LHB_Tech_Development_Volum... - RDSO - Indian Railway

केवऱ कायााऱयीन उपयोग हेत ु

(For Official Use Only)

भारत सरकार GOVERNMENT OF INDIA

रेऱ मंत्राऱय MINISTRY OF RAILWAYS

0

Hand Book

on

Maintenance Instructions for New

Technological Developments in LHB

Coaches

Volume 2 – System Documentation

IRCAMTECH/GWL/MECH/2021-22/LHB/HB/1.0

JULY, 2021

LHB Technological Development System Documentation


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Volume 2

System Documentation

All rights reserved. This book or any portion thereof may not be reproduced or used in any manner whatsoever without authorization from Indian Railways.

Content in this document is compiled with the inputs provided by ICF, MCF, RCF and OEMs



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Amendments and Revisions

The correction slips to be issued in future for this report will be numbered as follows:

IRCAMTECH/GWL/MECH/2021-22/LHB/HB/1.0# XX date .......

Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

Version Date Corrections Remarks

1.00 31/07/2021 First Release --



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Content

1 Technical Description

2 Cleaning

3 Maintenance Schedules

4 Tools andSpares

5 Maintenance

6 Drawing Index

7 General Information

8 Troubleshooting



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THIS PAGE IS INTENTIONALLY LEFT BLANK

LHB Technological Development 1. Technical Description


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1. TECHNICAL DESCRIPTION

Version : 1.00

All rights reserved. This book or any portion thereof may not be reproduced or used in any manner whatsoever without authorization from IndianRailways.




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Amendment and Revisions


1.00 31/07/2021 First Release --



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Table of Content

1. TECHNICAL DESCRIPTION .................................................................................................... 6

1.1.1. GENERAL .................................................................................................................. 9

1.1.2. COACH DESCRIPTION ............................................................................................... 9

1.1.3. CARBODY PART ...................................................................................................... 10

1.1.3.1. CARBODY SHELL ..................................................................................................... 10

1.1.3.2. DOORS .................................................................................................................... 12

1.1.3.3. WINDOWS .............................................................................................................. 14

1.1.3.4. Improved sidewall and ceiling panels .................................................................... 15

1.1.4. INTERIOR EQUIPMENT ........................................................................................... 16

1.1.4.1. SEATS ...................................................................................................................... 16

1.1.4.2. GANGWAY .............................................................................................................. 18

1.1.4.3. Collapsible Partitions & Foldable Luggage Racks ................................................... 19

1.1.5. PANTRY................................................................................................................... 19

1.1.6. TOILET .................................................................................................................... 19

1.1.6.1. Vacuum Assisted Flushing with Bio-toilets ............................................................ 20

1.1.6.2. Child Protection Seat ............................................................................................. 21

1.1.6.3. Odour Control Dispensers in the Aisle and Toilet .................................................. 21

1.1.7. WATER LEVEL INDICATOR ...................................................................................... 21

1.1.8. BRAKE ..................................................................................................................... 22

1.1.9. FIRE AND SMOKE DETECTION AND SUPRESSION .................................................. 22

1.1.9.1. Passenger Coach .................................................................................................... 22

1.1.9.2. Fire suppression system in power cars .................................................................. 23

1.1.9.3. Fire Extinguishers with anti-theft alarm ................................................................ 23

1.1.10. ELECTRICAL EQUIPMENT ....................................................................................... 24

1.1.10.1. Passenger information system integrated with the infotainment system ............ 24

1.1.10.2. Public Address System ........................................................................................... 25

1.1.10.3. Emergency Talkback System .................................................................................. 25

1.1.10.4. CCTV ....................................................................................................................... 26

1.1.10.5. Energy Harvester Based Diagnostic ....................................................................... 26

1.1.10.6. Digital Destination Board ....................................................................................... 27

1.1.10.7. Passenger Information and Coach Computing Unit (PICCU) ................................. 27



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TECHNICAL DESCRIPTION

1.1.1. GENERAL Since the first use of LHB coach in 2000, this coach was widely adopted due to its lightweight construction and high safety and comfort standards. To match up the world standard many new features were introduced into the coach.

The introduced feature of LHB design coachfocuses on future vehicle developments of the country,with its numerous technical innovations and intelligent solutions. The flexible and modular design represents a new innovative concept for long as well as short distance passenger traffic on high-speed lines of Indian Railways.

1.1.2. COACH DESCRIPTION

The vehicle is designed in such a way that it represents a strong and lightweight construction made from low-corrosive and stainless steels meeting all static and dynamic operational requirements. Thus, maintenance expenses are considerably reduced for the entire service life.

To increase the speed up to 200kmph changes have been made in the brake system. Bogie component have been changed as per load requirement. To provide futuristic looks vinyl wrapping with attractive graphics are used. To facilitate convenient inter coach movement sealed gangways have been provided. The new variants of LHB have been provided with modern amenities like automatic plug doors, automatic internal sliding doors, vacuum bio-toilet, electrically controlled opalescence on windows,GPS based PIS/PAS with digital speed indication, hot spot for infotainment, CCTV Cameras, mini pantry and numerous other technologies

Following coaches have been rolled out by Indian Railways. Each type of coach has their unique features which have been provided as per requirement.

Tejas: These coach are being used in Tejas Express, India's first semi-high speed fully air-conditioned train. It features modern onboard facilities such as sealed gangways, vacuum bio-toilet, motorized blinds for windows, internal automatic sliding door, Infotainment system , single leaf plug doors which are operated automatically and much more.

Humsafar: Humsafar Express is a premium service with AC-3 Tier Sleeper Class accommodation having all the modern facilities for long haul routes. It features onboard facilities such as CCTV, PIS, fire & smoke detection system, beverage vending machine, child protection seat & automatic urinals in toilet and much more.

Anubhuti: These type of coaches will be provided in the executive class of premium trains such as Shatabdi and Rajdhani. Plush upholstery, designer toilets, diffused lighting, better ergonomics, LCD screens, and personalisedpantries are some of its features.

Smart:With the use of Smart Coach ,Indian Railways aims to move to predictive maintenance instead of preventive maintenance. Smart Coach will provide world-class facilities to passengers with the help of an intelligent sensor-based system. Switch Cabinet Board, GPS based Public Announcement System, CCTV and RMPU monitoring, passenger talkback, digital destination board, energy harvester based sensor are some of its main features.



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Uday: These are used in completely Double-Decker AC chair car trains, and will cater to the "busiest routes" and increase carrying capacity by 40%. These coaches are lighter coach by virtue of monocoque design with a unique diamond shape under frame. Comfortable Shatabdi style seats, LCD screens with Wi-Fi, GPS based passenger information system, modular bio-toilets with soap dispensers, fire & smoke detection system, pantry and dining area in every third coach are some of its notable feature.

Antyodaya: Antyodaya Express is completely unreserved/general coaches. The trains have only general coaches designed by Indian Railways with features such as vestibule for inter-coach movement, improved sidewall and ceiling panels, wider sliding windows, improved Modular FRP toilets, cushioned luggage rack and fire extinguishers with anti-theft alarm.

AC 2T in 3 Tier Shell: Need for more head space for upper berth in AC 2 Tier type coach was always been felt and MCF has taken an initiative to useAC 3 Tier Roof profile with necessary design changes to mount seats and berths as per AC 2 Tier requirement. This development resulted 260 mm more headroom for upper berth passenger in compartment area.

High Capacity Parcel Van: This is the first ever High Capacity Parcel Van on LHB platform.It has total carrying capacity of 24 ton and total volume of 187 m3 to facilitate transportation of wide goods, foldable 2-tier luggage racks have been provided. These coaches have three collapsible partitions and four numbers of sliding doors.The coach has complete stainless steel interior panelling and fitted with 140 KN air suspensions.

AC 3-Tier Economy: The AC 3-tier economy is touted to be the Railways' most affordable class of air-conditioned travel. The design of the coach includes a redesigned AC duct to provide individual vents for each berth. The coach also has an improved and modular design of seats and berths, foldable snack tables in both longitudinal and transverse bays, injury-free spaces and holders for water bottles, mobile phones and magazines.Additional berths have been provided in the coach as the number of berths in the new coach has been increased from 72 to 83

1.1.3. CARBODY PART

1.1.3.1. CARBODY SHELL Economical light weight steel construction with interlocking technique. Roof of beaded sheet construction with roof arches. Corrugated sheet floor and roof sheeting are made of stainless steel.Roof framework, sidewall and end-wall complete are made of semi stainless steel.

Monocoque Shell Design The Uday coach has unique design not only because of double decker design, but it relies on unique diamond shape under frame to carry the UIC standard 2000kN compressive load also. Besides, the design has been simulated for crashworthiness to take an impact load of over 5 Mega Joule. Shell design comply UIC 566 for static load condition and GMRT 2100 for crashworthiness design. Coach body structure is of stainless steel except for under frame which is fabricated with Corten steel.

Vinyl wrapping on the exterior Vinyl wrapping with aesthetically pleasing design has been provided on the exterior of the coach. Such can be observed in coaches of Tejas ,Humsafar, Uday, Antyodaya etc.



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Vinyl wrapping in Tejas Coach

AC-2T coach using of LHB AC-3T Roof profile Need for more head space for upper berth in LHB AC – 2 Tier coach was always been felt. MCF has usedLHB AC – 3 TierRoof profile with necessary design changes to mount seats and berths as per AC – 2 Tier requirement.

This development resulting in 260mm more headroom for upper berth

passenger in compartment area.

This has also given flexibility to produce both variants on single shell design.

AC-2Tierwith AC-3Tier Roof profile

3-Tier Roof Profile

Increased Headroom



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1.1.3.2. DOORS

Automatic Internal Sliding Doors Interior sliding doors serve to separate the boarding area of the vehicle from the seating area with advantages of the solution: reliability and comfort of operation. The interior door can be controlled either by a radar signal when the person approaches or by pressing a button on the door.In case of power failure, the doors are freely movable manually or in case of emergency, the door is disconnected from the power supply when emergency button is pressed and is freely movable manually.

Automatic Internal Sliding Door

Press button for opening the door Emergency button

Automatic Single Leaf Plug Doors Automatic single leaf plug doors facilitate alighting boarding of passenger into the trains. The Automatic sliding Single Leaf Plug doors installed in the rake are controlled by centralized door control equipments via hardwired train lines installed in Guard's compartment. Guard



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panel have push buttons to activate the doorfunctional commands. Emergency door opening switch is also provided on the door. Train moves only after all the entrance doors are closed and entrance doors open only when train comes to a halt. In case the train starts operation, all doors (independently which one) will automatically close when the speed is greater than 5 km/h. These doors enhance the safety of the passengers.

Automatic Plug Door in Tejas Coach

Automatic Hinged Door Automatic door locking and opening mechanism in coach access doors is a sophisticated hinged type system in which train will only able to run from Railway station when the coach doors are in closed condition. Similarly these doors remain closed till the train stops at the next station and eliminate chances of passengers detraining from the moving train. These doors can be locally opened by pulling Emergency pulling chain and by pressing Door emergency button when train get stopped in emergency condition. All doors of one side (Left or Right depends upon platform side) of train can be opened by pressing push buttons available in door controller, will decided by guards. When the doors are open, the train should not be able to start. Controls of these doors will be available at guards/ Train crew.

Automatic Hinged Type Doors



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Pocket Sliding Doors

High Capacity Parcel Van has four pocket sliding main door for easy & rapid loading unloading.

High Capacity Parcel Van with Sliding Main Doors

1.1.3.3. WINDOWS

Motorized Blinds The windows of the new coacheshave motorized blinds. Initially provided in Tejas Coach passengers are provided with a button next to the window, which can be used to roll the blinds up and down.

Motorized Blinds in Tejas Coach

Electrically Controlled Roof Opalescence Glass Unit This is a important feature provided in Vistadome Coach. The Opalescence feature plays a vital role in controlling the incoming sun light by electrically controlling its transparent feature to opaque. Totally 10 (5 Left Hand and 5 Right Hand) opalescence glass units are provided in the roof and they are controlled by a single control box unit fitted inside the



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Service station.

Electrically Controlled Roof Opalescence Glass Unit in Vistadome Coach

Observation Lounge A dedicated Observation lounge is provided in Vistadome Coach with panoramic viewing windows and a Utility table.

Observation Lounge of Vistadome Coach

Wider Sliding Windows Wider sliding type glass windows with aluminum frame(which is glued to the sidewall like in AC LHB coaches) have been provided. These windows has wide viewing angle for passengers and better aesthetics. Such windows have been used in Antyodaya Coaches.

Wider Sliding Windows in Antyodaya Coach

1.1.3.4. Improved sidewall and ceiling panels

In Antyodaya Coach the complete interior furnishing has been upgraded by providing FRP sidewall panels in quad coloration color scheme and FRP ceiling panels with two tone



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colorfinish in place of blue color LP sheet and white color NFTC respectively.

Ceiling Sheets Sidewall Panels

1.1.4. INTERIOR EQUIPMENT

1.1.4.1. SEATS

Improved chair with E-leather (eco leather) as upholstery material has been provided in Tejas coaches. In executive class chair cars, leg support has alsobeen provided which are controlled by gas spring.

E-Leather is a unique, sustainable upholstery material. It is known for its longevity without the need for frequent and invasive deep-cleaning.

E Leather seats in Tejas Coach

180 DEG. ROTATABLE RECLINING PASSENGER SEATS Vistadome coach is the 180 degree Rotatable Double seater offers a panoramic view of the surroundings to the passengers. Like in other elite coaches, these seats also have reclining



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operation, charging socket under each seat, Snack tables can be unfolded from arm rest, Bottle and Magazine holder in the back rest of each front seat. Additionally each pair of seats are mounted to the floor by a single shaft mechanism that allows the seat to be rotated on any direction as per the passengers wish. A Push button beneath the Arm rest will allows the back rest to be reclined. A 3 step adjustable foot rest for each seat is given below the front seat of each seat.

180 degree Rotatable Seats in Vistadome Coach

Cushioned Luggage Rack Cushioned luggage racks have been provided in Antyodaya coaches for use as seats during rush time.

Cushioned Luggage Racks in Antyodaya Coach

Modular Seats/Berths and Amenities The design for AC 3 Tier Economy Coach includes a redesigned AC duct to provide individual vents for each berth. The coach also has an improved and modular design of seats and berths, foldable snack tables in both longitudinal and transverse bays, injury-free spaces and holders for water bottles, mobile phones and magazines.Individual reading lights and mobile



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charging points are provided for each berth in addition to standard sockets.

Side Berth of AC 3T Economy Coach

Modular Berth of AC 3T Economy Coach

View of Aisle in AC 3T Economy Coach

1.1.4.2. GANGWAY

In Tejas Coach the gangways are fixed between two coaches as a single unit instead of conventional gangway vestibule where two separate units are fixed on adjacent coaches. Due to this, it has better sound levels, reduced dirt, sand and water ingress and better passenger safety and comfort.



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Sealed Gangway in Tejas Coach

1.1.4.3. Collapsible Partitions& Foldable Luggage Racks

In High Capacity Parcel Van three collapsible partitions with four compartments is provided for modular use. These coaches have foldable 2 tire luggage racks. These facilitate transportation of wide goods.

Inside View of High-Capacity Parcel Van

1.1.5. PANTRY Pantry compartment for storing, preparingand serving of precooked food,snacks andbeverages with equipment like refrigerator,hot case,beverage vending machine, waterpurifier and microwave oven. Such minipantry is available in Vistadome Coach. For other coach where mini pantry is not available, equipment such as chiller, hot case andbeverage vending machines have been provided.

1.1.6. TOILET Improved toilet system with touch-less fittings for water tap and soap dispensershave been provided for clean experience. Also the interior aesthetics have beenimproved substantially

MMini-Pantry in Vistadome Coach



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by marble paint finish with anti graffiti coating, gel coated wash basin shelf, new design dustbin, door latch activated light and lavatoryengagement display.

Modular Toilet Fittings

Toilet Engagement Indictor

1.1.6.1. Vacuum Assisted Flushing with Bio-toilets

Due to vacuum assisted flushing, water consumption per flush is less and effectiveness of flushing is higher resulting in cleaner and more hygienic toilets.

Working of Vacuum Assisted Toilet



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1.1.6.2. Child Protection Seat

Toilets are provided with Child Protection seats for holding toddlers travelling with single parent for the convenience of using toilets. Such seats are available in Humsafar Coach

Child Protection Seat in Humsafar Express

1.1.6.3. Odour Control Dispensers in the Aisle and Toilet

Odour control dispensers have been provided in the aisle and toilet.

Odour Control System

1.1.7. WATER LEVEL INDICATOR Water level indicator is used to indicate the level of water in the tank at convenient place from where the level of water in tank can be seen in trains during journey. It helps railway staff in taking decision to fill up the tank at coach watering station.

Primary Display/Controller Unit Secondary Display Unit Installation Position



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1.1.8. BRAKE To increase the maximum speed up to 200kmph, existing Axle mounted discbrake system has been upgraded with:

Steel brake disc (in lieu of grey cast iron brake discs)

Sintered brake pads (in place of composite brake pads)

Additional EP assist brake system

Organic Pad Sintered Pad

1.1.9. FIRE AND SMOKE DETECTION AND SUPRESSION

1.1.9.1. Passenger Coach

The complete rake has been provided with fire and smoke detection system. The system has smoke sampling points provided at various locations in the compartment area (8 nos), doorway area (2 nos.) and electrical panel area (1 no.) Heat activated sensors are provided in all the 3 lavatories. On sensing of smoke/heat, depending upon the level of smoke, the system activates audio visual alarm and passenger announcement activation. After certain level/time automatic application of brake is initiated. A central monitoring system (CMS) is provided in each coach and a central monitoring unit (CMU) is mounted inside crew room of power car. The CMU displays the status of each coach of the rake.

Fire Detection System Installed in Coaches



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1.1.9.2. Fire suppression system in power cars

All the power cars in the rake have been provided with smoke detection and fire suppression system. The system consists of one number high pressure Nitrogen cylinder and 2 nos. water cylinders which are connected with 10 nos. of nozzles provided inside the generator room to disperse water mist. Heat and smoke detectors are installed above the generators. The detector control panel is provided inside the crew room. In case of smoke/fire, the alarm/buzzer is sounded and on detecting the fire, crew members are needed to operate a manually operated trigger valve for initiating suppression. Operating of trigger valve releases the high pressure nitrogen with water and water mist is discharged in engine compartment.

Water and Nitrogen Cylinders in Power Car

1.1.9.3. Fire Extinguishers with anti-theft alarm

Fire extinguishers with anti-theft alarm have been provided in Antyodaya coaches. A buzzer sounds whenever fire extinguisher is taken out from housing which also alerts passengers.

Fire Extinguisher with Anti-Theft Alarm



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1.1.10. ELECTRICAL EQUIPMENT

1.1.10.1. Passenger information system integrated with the infotainment system

The coaches are provided with infotainment system in the form of LCDscreens mounted on the back of chairs. The infotainment system has featuresfor displaying of recorded content like entertainment media, advertising, safety instructions etcand can also be upgraded for live TV viewing. This infotainmentsystem has also been provided with integrated GPS based passengerinformation system. For this, LCD screen has one separate channel fordisplaying the data from GPS based passenger information system. Moreover,USB charging facility has also been provided with each screen.

PIS Integrated Infotainment System

Passenger Information System Such technology is included in several coaches which include Humsafar, Uday etc.PIS system comprising of Master Board Unit, GPS receiver and LCD screendisplay panel above the passenger compartment doors has been provided ineach coach to display the Welcome/farewell messages and information regardingcurrent time, current station, next stations, remaining distance and late runningstatus in Hindi, English and Regional Language.



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The safety slogans are alsodisplayed intermittently.

PIS in Humsafar Coach

1.1.10.2. Public Address System

PA system comprising PA Amplifier and speakers in each coach has been provided which are connected to the main amplifier with the help of PA Couplers for interconnection of the coaches in the rake along with a speech unit which is used for Public address as per the requirement.

Public Address System

1.1.10.3. Emergency Talk back System

This facility is provided in Smart Coach. Incaseofamedical or securityemergency,apassengerwillbeabletogenerateacallregisterforthetrainsupervisor.Thisfeaturewill Improveresponsetimeofstaffandalsoreducechainpullingsignificantly.

Talk Back Unit in Smart Coach



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1.1.10.4. CCTV

The coaches like Humsafar have CCTV installedat both the ends.06 nos. of high resolution cameras (2 in passengerarea, 2 nos. in each doorway area) have beenprovided. Cameras has night vision capability andfacial recognition in low light condition. A networkvideo recorder (NVR) has been provided in eachcoach with 2 TB hard disc capacity. The systemhas 30 days loop recording provision and works 24hours per day. Additional 32GB SD card has alsobeen provided to work as stand by to hard disk. Incase of failure of camera/hard disc, indication isshown on NVR. Real time tagging of videos withspeed, location and time through GPS antenna canalso be done.

CCTV Camera Unit in LHB Coach

Analytics CCTV Analytics module (facial recognition system) is capable of capturing, andidentifying a person from a digital image or a video frame. Such a system is provided in Smart Coach.

Analytics used for Facial Recognition in Smart Coach

Blacklisted person face images can be saved. In case the blacklisted person appears and gets detected in front of camera. Check will be generated in alert window.

1.1.10.5. Energy Harvester Based Diagnostic

The Energy harvester based sensor monitors the condition of wheel, bearing and hard spots on the Track. The same is fed to the data concentrator and transmitted via GPS/GPRS to a remote server. The data can be used for diagnosis.Wheel defects, bearing defects are both reported up to 6months prior to their becoming critical, giving sufficient time to schedule maintenance time. This technology has been used in Smart Coach.



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Vibration Energy Harvester in Smart Coach

1.1.10.6. Digital Destination Board

In Smart Coach, LED Digital Destination Board has been installed. This has been done by reducing the Display board size by splitting the displayed data in to two rows: Row1: Train number and Coach Type Row2: Scrolling text display of destination and intermediate station in multiple languages. Optimizing character height to 80mm for rationally arrived at 25m visibility.

Digital Destination Board in Smart Coach

1.1.10.7. Passenger Information and Coach Computing Unit (PICCU)

Smart Coach has a Passenger Information and Coach Computing Unit (PICCU) a CPU that is a similar to an industrial grade computer. This has been provided with GSM network which sends execution reports to the remote server. PICCU will monitor important areas of coach maintenance and passenger interface.



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Passenger Information and Coach Computing Unit (PICCU)

It is a powerful expandable computing device based on Open Source Technologies that integrates all Control Systems related to Passenger Comfort or coach performance to a single web interface. Using industry standard Apps that may come from the PICCU OEM (pre-installed applications) or may be developed by third parties using the API documents provided by the OEM, PICCU performs an expandable platform. Its key feature is:

Fan-less and Fully Sealed

Best in-Class processor

Capacitive 7" touch Screen

Anti vandal Touch Panel

Inbuilt GPS

Inbuilt GSM/GPRS modem

Wi-fi enabled

Expandable

Highly Rugged design

LHB Technological Development 2. Cleaning


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2. CLEANING

Version : 1.00


Content in this document is compiled with the inputs provided by ICF RCF, MCF and OEMs



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1.00 31/07/2021 First Release --



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Content

2. CLEANING ............................................................................................................................ 1

2.1. INTERNAL CLEANING ........................................................................................................... 4

2.1.1. GENERAL .............................................................................................................................. 4

2.1.2. DEFINITION .......................................................................................................................... 4

2.1.3. INTERIOR CLEANING (NORMAL) .......................................................................................... 4

2.1.4. INTERIOR CLEANING (INTENSIVE) ....................................................................................... 5

2.1.4.1. VACUUM BIOTOILET ............................................................................................................ 5

2.1.4.2. AXLE MOUNTED DISC BRAKE SYSTEM (Knorr Bremse) ....................................................... 6

2.1.4.3. AXLE MOUNTED DISC BRAKE SYSTEM (Faiveley Transport) ................................................ 6

2.1.4.4. ELECTRICALLY CONTROLLED OPALESCENCE – ROOFTOP (PrivaLite) ................................... 7

2.1.4.5. CHILD PROTECTION SEAT (Euronics) ................................................................................... 8

2.1.4.6. E-LEATHER SEATS (SUTLUJ) ................................................................................................. 8

2.1.4.7. AUTOMATIC HINGED DOOR (IMI) ...................................................................................... 8

2.2. EXTERNAL CLEANING ........................................................................................................... 8

2.2.1. SEALED GANGWAYS (Hubner) ............................................................................................. 9



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2.1. INTERNAL CLEANING

2.1.1. GENERAL It is to be noted that the cleaning instruction to be followed during the internal and external cleaning of LHB Coach.

2.1.2. DEFINITION Clean: Re-create clean external and internal conditions Damp wipe: For “damp wipe”, all work must be undertaken with a damp cloth without the addition of any cleaning agent. Wash: All following work designated "wash" must be undertaken with a cloth dampened with a non- aggressive cleaning solution. Wash over and wipe clean: Cleaning glass surfaces with the aid of water, cleaning agent and cleaning implements. Take up loose dirt from the floor: Use dustpan and brush, broom or similar equipment to sweep up general loose dirt from the floor, collecting larger items manually. Unusual contaminants: All troublesome soiling, requiring use of special cleaning agents or methods for removal Emptying: All rubbish, including any wedged-in. Clean up: Waste-bins, ash-trays and similar equipment, returning them to their places.

2.1.3. INTERIOR CLEANING (NORMAL) Complete Vehicle Collect all rubbish, if possible dividing according to type, using plastic sacks in the same operation, rubbish bins and similar containers.

Sweep up dirt on the floor with dustpan and brush, causing as little dust to fly as possible. As the vehicle is air conditioned it is recommended to use vacuum cleaner.

Replace seats bins, rubbish bins and similar containers in their appointed places.

Clean the pantry cabin. Remove food packet cover, wrappers or any bio degradable waste. Stain mark on electrical appliance to be cleaned after switching off the power supply.

Check vacuum bio-toilet, for cleanliness. If required to be done as per recommendation only. Wash basin and taps, mirror and floor to be checked for cleanliness.

Check for cleanliness of inspection windows and windshields (inside and outside).Automatic and sliding door glass to be checked for cleanliness. If required to be cleaned with mild detergent.

Use a basic soft brush or a vacuum to remove loose debris and wipe with a lightly moist cloth for seats with E-Leather.

Note : Air freshener should be sprayed after completing the cleaning process or as and when required

Warning: 1. When cleaning areas which cannot be reached from the floor, steps must be used. 2. Never stand on the seats, equipment boxes or their cabinets. 3. Special care to be taken while cleaning glasses and equipment to prevent injury.



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4. Guideline to be followed as per Railway Board’s letter, reference no: 2016/EnHM/06/09 Dated 23/08/2018

2.1.4. INTERIOR CLEANING (INTENSIVE) Complete Vehicle Damp wipe racks, handrails and covers with light wiping-cloth.

Marks to be removed from ceilings, walls, doors, visible surfaces, trim-panels, covers, light-fittings.

Dirty marks on mirrors and windows to be sprayed with glass cleaner and wiped with a clean soft cloth.

Clean the floor. Remove troublesome, loose dirt (e.g. crumbs, sand) from upholstery with either an recommended brush or a vacuum cleaner.

Damp-wipe handrails, door-handles, door-pushes and emergency handles.

Note: List of chemical used in cleaning of coaches as per Railway Board’s letter, reference letter : 2016/EnHM/06/09 Dated 23/08/2018.

Warning: 1. The cleaning staff should take necessary precautions. Personal protective equipment

must be used. 2. The toilet used in this train is vacuum assisted bio-toilet. Only approved cleaning

agent as per Compendium on bio-toilet issued by IRCAMTECH and OEMs to be used. 3. CARE MUST BE TAKEN that no water is allowed to get into the ventilation slits,

partitions, at the seats and hand-holds, floor-plates, articulation joints and surrounding areas or in the corridor connection.

4. CARE MUST BE TAKEN that no water is allowed to get into equipment.

2.1.4.1. VACUUM BIOTOILET Do not dean polished stainless steel toilet pan with a brush as it may scratch the

surface of the toilet pan. The polished surface prevents any dirt from sticking to it and shortens the time needed for cleaning the toilet.

Use only water and approved washing agents during regular maintenance works on the toilet.

Discoloration on the surface can be removed using mild soap solution.

Do not use any chemical agents. like aggressive acids or strong bases for cleaning/maintenance.

Using such chemical agents may result in weakening of the rubber elements inside the valves which may result in the loss of tightness and incorrect operation of the vacuum toilet.

Such chemicals on entering bio-toilet will affect the bacteria culture.

Water supplied to the toilet must flow through mesh filter/Y-strainer to avoid chocking of pan nozzles.

Toilet pan has to be covered during hard reserve cycle for safety reason while removing the major block in toilet pan.



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Following Instruction to be followed while using vacuum bio toilet system Note: Instruction as mentioned below can be pasted beside toilet so that it can be easily read

The manufacturer recommends not to throw any objects like cigarettes, cotton swabs, medicine, needle, paper towels, wipers, diapers, sanitary napkins. gutka or toffee wrappers, pencil, pen, bottles, plastic /metal objects, chemical substances etc or any other object inside the toilet pan, since it can cause break down.

Do not flush the toilet while seated. Close the lid before flushing and open the lid after flushing cycle is completed.

2.1.4.2. AXLE MOUNTED DISC BRAKE SYSTEM (Knorr Bremse) After removing of parts from an item or equipment should examined for reusability. All the parts that do not have to be exchanged needs to be cleaned properly.

The cleaning method depends upon the component to be cleaned, the degree and the type of dirt to be removed and the facilities available.

Clean the exterior of the equipment / assembly with a low air jet to remove the outer dirt. After removal of sub- assemblies, wipe the exterior portion with a clean cloth. Blow a low pressure jet of dry compressed air inside the machined bores, cored passages, port holes, cavities and seating grooves on the sub- assemblies. Wipe the parts with a clean cloth and allow them to dry on a clean surface on the work table.

Care should be taken to protect the finish on the various components while placing, as far as possible avoid keeping the components piled up one over the other.

All the rubber items such as Gaskets, O rings, seals, Diaphragms, nylon filter/strainer etc. are to be cleaned only with detergent dissolved in warm water or soap water solution. Dry them with a blow of jet of compressed air and wipe them clean with soft cloth. They should never be exposed to petroleum or chemical cleaning solvent.

Use clean low pressure to clean the chokes / choke passages, if required use a wire of smaller diameter without using a sharp tool to clear the clogging.

The cleaning agent manufacturers’ direction for the use of cleaning agent must be observed.

2.1.4.3. AXLE MOUNTED DISC BRAKE SYSTEM (Faiveley Transport) The cleaning method depends upon the component to be cleaned, the degree and the type of dirt to be removed and the facilities available.

Whatever cleaning agents are used; due care must be taken to ensure the health and safety of the personnel involved. The manufacturer’s recommended safety precautions including the use of approved cleaning plant must be followed. Since every installation is different, the responsibility for safety lies with the user and the manufacturer of the cleaning plant and materials. However, general guidelines on the cleaning procedure for the air brake equipment during maintenance and scheduled overhauls as under are recommended.

Blow the exterior of the equipment / assembly with a low-pressure jet of air to remove the external dirt. After removal of sub-assemblies, wipe the exterior portions with a cloth.

Clean with environment friendly agents like White spirit, etc. all the stripped components by using a cloth or nylon bristle brush based on the sensitivity of item. If kerosene is used,



Page Page 7 of 9

special care must be taken in protecting the user with proper gloves as well as the environment from the likely fumes. Sufficient care is to be taken to ensure that the residual deposit of kerosene, if trapped inside the cavities / bores of the components, is removed thoroughly before the components being re-used. In addition, the contaminated kerosene after use should also be disposed of by proper environment friendly action.

Blow a low-pressure jet of dry compressed air inside the machined bores, cored passages, port holes, cavities and seating grooves on the sub-assemblies.

Wipe the parts with a clean lint free cloth and allow them to dry on a clean rubber sheet on the work table. Take good care to protect the finish on the various components and place them. Avoid keeping the components piled up one over the other.

All rubber components including rubber seated valves must not be exposed to petroleum or chemical cleaning solvent. Items like Gasket, “O" Ring, Seal, Diaphragm, Nylon filter / Strainer etc., are to be cleaned only with a detergent dissolved in warm water or soap water solution. Blow a jet of compressed air in the reverse direction on the Nylon Filters and wipe clean with soft cloth.

Chokes / Choke passages are to be cleaned by a blow of clean low pressure air jet. Clogged chokes may be cleaned with a wire of smaller diameter without using a sharp tool. Application and Release choke plugs, in DV valve body are to be cleaned, blown with air, and kept free of dirt/dust, grease, paint, etc., by suitable covering till they are fitted.

Caution: While cleaning the equipment / components with chemical / petroleum compounds, care must be taken to prevent inhalation of fumes emanating from the cleaning agent and for any possible injury to persons handling the equipment. Similarly, for any chemical fumes likely to cause a fire hazard, steps must also be taken for adequate protection to equipment/ installation.

2.1.4.4. ELECTRICALLY CONTROLLED OPALESCENCE – ROOFTOP (PrivaLite)

Warning:

Clean the PRIVA-LITE like any other glazing.

Make sure that PRIVA-LITE panel is OFF when cleaning it.

Regular cleaning with neutral materials is recommended for optimum performance.

Use A soft, clean lint-free cloth or chamois leather. Or a clean, soft non-abrasive sponge. Or a clean, non-metal window squeegee.

Warning:

Do not use steam cleaners (Polti) or pressure cleaner (Kärcher) as this would generate water infiltrations and short circuits, and bring temperatures over 60°C.

All cleaning tools must be kept clean. This is to prevent any dirt or abrasive particles transferring from the equipment back onto the glass which may scratch or damage the glass.

Use the softest water as possible in reasonable quantity. Hard-water may leave marks after drying. Preferably use softened or demineralised water. If this is not possible, then a little liquid soap can be used to soften water.



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- Do not spray water on the glass. This is contradictory with the use of a squeegee.

All glass cleaners based on alcohol or ammoniac are suitable for the use with PRIVA-LITE.

Forbidden cleaners and cleaning tools are basically those that can alter the glass, the Mutisil silicone or the frames, either chemically or by abrasion such as:

Glass treatment products containing silicones or abrasive particles.

Corrosive liquids

Commercial cleaning products which are intended specifically for cleaning elements other than glass.

Chemical products: acetone, soda, bleach, washing powder, white spirit etc.

Sharp or abrasive objects including jewellery, buckles, tape measures, razor blades, Stanley knives, scouring pads, steel wool, sandpaper etc.

Never attempt to clean off a specific mark on the surface of PRIVA-LITE without applying little water first.

2.1.4.5. CHILD PROTECTION SEAT (Euronics) The unit manufactured by the antibacterial HDPE, helps reduce the risk of cross-contamination.

Use mild soap solution to clean the seat at regular intervals.

2.1.4.6. E-LEATHER SEATS (SUTLUJ) Apply detergent spray or foam to the recommended cleaning pad (3M Ultrafine abrasive pads or equivalent) and wipe or rub the surface of the upholstery to remove any soiling. Repeat if necessary.

Next, remove the excess moisture and wipe dry with a soft cloth.

If required, apply leather conditioner with a soft non-absorbent cloth.

Note :

Do not carry out deep cleaning for more than a month.

E-Leather is a unique, sustainable upholstery material. It is known for its longevity without the need for frequent and invasive deep-cleaning.

2.1.4.7. AUTOMATIC HINGED DOOR (IMI) During internal floor washing of coaches, system has to cover “Control Block” to avoid entering of water into the system.

During internal floor washing of coaches, system has to cover “Emergency Reset/ Mechanical Locking valve” to avoid entering of water into the system.

Power supply must be protected from water or moist.

2.2. EXTERNAL CLEANING Removal of dirt/dust on window bars/exterior panels. For roof top equipment and curved surface, dust should be dislodged using a

suitable brush and pressurized air.



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All exterior panels including end panels to be cleaned with application of appropriate exterior coach cleaning compound and then washed with high pressure jet.

Inspection of windows glasses have to be cleaned and wiped dry thoroughly using glass cleaning solvent and squeeze.

Hand rails and steps should then be washed and wiped clean free of dust and dirt. Care should be taken to wash and clean body panels under the handrails using special brushes manually. All water & detergent marks shall be removed after the cleaning and washing.

For Under frame the affected area to be identified by visual inspection. Accumulated dirt/dust etc to be cleaned with damp cloth and then drying by compressed air.

Note:

Exterior cleaning to be done as per below mentioned documents Railway Board’s letter, reference no: 2016/EnHM/06/09 Dated 23/08/2018.

Precaution to be taken that equipment and machinery will not be started inadvertently.

Precaution to be taken that there is no movement of the coach during under-frame component cleaning.

Precaution to be taken that the equipment to be cleaned is electrically isolated.

2.2.1. SEALED GANGWAYS (Hubner) The following cleaners can be used to clean the gangway:

a) For slight soiling:

pH neutral industrial cleaners (pH6 - pH8)

b) For strong soiling or Graffiti-soiling cleaners on the basis of citric or orange acid can be used:

Grafforange

Comorcap LP

LHB Technological Development 3. Schedule


Page Page 1 of 38

3. MAINTENANCE SCHEDULE

Version : 1.00


Content in this document is compiled with the inputs provided by ICF RCF, MCF and OEMs



Page Page 2 of 38



1.00 31/07/2021 First Release --



Page Page 3 of 38

Table of Content

3. MAINTENANCE SCHEDULE .................................................................................................. 1

Amendment and Revisions ........................................................................................................ 2

Table of Content ......................................................................................................................... 3

3.1. MAINTENANCE INTERVAL .............................................................................................. 4

3.2. SCHEDULE ACTIVITIES FOR EQUIPMENT ........................................................................ 4

Automatic Sliding Door (PARS COMPONENTY) .......................................................................... 4

Single Leaf Plug Doors (iFE) ........................................................................................................ 5

Automatic Hinged Door ( BONY/IMI) ......................................................................................... 6

Sealed Gangway (HUBNER) ........................................................................................................ 8

Vacuum Biotoilet (AMIT ENGINEERS) ........................................................................................ 9

Water Level Indicator ( Amit Engineers) .................................................................................. 10

Vacuum Biotoilet ( OASIS Fabrications) ................................................................................... 10

Odour Control System (JADE)................................................................................................... 12

Fire Detection and Suppression System (SANROCK) ............................................................... 12

Fire Detection And Suppression System (FOGTECH) ............................................................... 13

Axle Mounted Disc Brake System ( KNORR BREMSE) .............................................................. 13

Axle Mounted Disc Brake System ( FAIVELEY TRANSPORT) ..................................................... 21

Electrically Controlled Roof Opalescence Glass Unit (PRIVA LITE) .......................................... 28

Seats (SUTLUJ) .......................................................................................................................... 28

Vacuum Biotoilet (GLOVA RAIL) ............................................................................................... 29

Annexure – I .............................................................................................................................. 30

Annexure – II ............................................................................................................................. 31

Annexure – III ............................................................................................................................ 33

Annexure – IV ........................................................................................................................... 37



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3.1. MAINTENANCE INTERVAL

Schedule Periodicity

Trip Every Trip/Weekly

Monthly Monthly ± 3 days

Six Monthly Half Yearly ± 15 days

Shop Schedule-1 (SS-1) 18 months/ 6 lakh kms whichever is earlier

Shop Schedule-2 (SS-2) 36 months/ 12 lakh kms whichever is earlier

Shop Schedule-3 (SS-3) 72 months/ 24 lakh Kms whichever is earlier

The interval to be observed is always the first reached by the vehicle.

Tolerance must not be allowed to exceed.

Service intervals predominantly depend on the mileage and the operating conditions of the vehicles.

3.2. SCHEDULE ACTIVITIES FOR EQUIPMENT

S.No Equipment/ Sub-Assy.

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1 Automatic Sliding Door (PARS COMPONENTY)

1.1 Maintenance

1

Checking the fluent opening and closing of the door - beware of noise, jerking motion, knocking

✓ ✓ ✓ ✓ ✓

2

Checking completeness of the mechanism, screwing up, binding cables, loose connections, etc. - visually

✓ ✓ ✓ ✓ ✓

3

Checking the door protection function - contact bar in the door leaf, over-current protection ($): Activity to be done bi-monthly (2 months interval)

✓$ ✓ ✓ ✓ ✓

4

Checking the drive screw system - replacing the plastic nut

✓ ✓ ✓ ✓

5

Checking end-position sensors of the doors - functionality, properly set switching

✓ ✓ ✓ ✓

6

Checking the bottom guides - replacing the plastic slider if necessary

✓ ✓ ✓ ✓

7

Checking the rubber sealing - replacing if necessary

✓ ✓ ✓ ✓

1.2 Lubrication



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Activities

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1

Lubricate travel bearings - ball bushings with ISOFLEX 18 ($): Activity to be done bi-monthly (2 months interval)

✓$ ✓ ✓ ✓ ✓

2

Lubricate motion screw with BERUCOAT-AF438

✓ ✓ ✓ ✓

2 Single Leaf Plug Doors (iFE)

1

Safety-Check in accordance with Safety-Checklist ( OEM Document - DDG10203E36 (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓ ✓

2

Check painting in accordance with OEM instructions.( OEM Document - DDG10203E01) (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

3

Visually check for flats at rollers of roller swing arm, roller on the door leaf carrier, and roller from roller bracket on the bottom door leaf area. Exchange defective component if required. (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

4

Clean door seals and re-grease in accordance with Lubrication instruction ( OEM Document - DDG10203E05) (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

5

Clean and re-grease guide rod in accordance with Lubrication instruction. .( OEM Document - DDG10203E05)

✓ ✓

6

Clean top guide rail and re-grease in accordance with Lubrication instruction. .( OEM Document - DDG10203E05)

✓ ✓

7

Visual inspection for cracks in the radius area (A) on the right and left trolley on drive unit and replace if necessary. Note :

I. Initial inspection is

✓*

✓(I) ✓



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Activities

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required after 3 years. Thereafter every 12 months.

II. Inspection is only required for trolleys without bevel on the trolley profile(B)

III. Above activity to be done on 12 months interval basis. (*) Every Alternate 6 Months (Yearly)

8

Clean drive spindle and re-grease in accordance with Lubrication instruction.( OEM Document - DDG10203E05

✓ ✓

9

Grease the components in the lock housing mechanism in accordance with Lubrication instruction. .( OEM Document - DDG10203R05)

✓ ✓

10

Grease the components in the isolating lock in accordance with Lubrication instruction. .( OEM Document - DDG10203E05.)

✓ ✓

Note : 5 & 10 yearly activity to be done as per Annexure - I

3 Automatic Hinged Door ( BONY/IMI)

3.1 Main Controller

1

Controller must be completely cleaned

✓ ✓ ✓ ✓ ✓ ✓

2

Check the wiring connection and condition if require tightening or changed, to be done.

✓ ✓ ✓ ✓ ✓ ✓

Note :



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Activities

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HMI screen should not be touched with Oiled/grease or dirty hand.

Screen must be protected from damage due to suddenly fall of metal or hard item.

Controller must be protected from entering of fluid items like water/oil or dust.

3.2 Local Door controller:

1

Check for any air leakage from actuator. If found corrective action need to be taken.

✓ ✓ ✓ ✓ ✓ ✓

2

Check for any damage by external agency, passenger.

✓ ✓ ✓ ✓ ✓ ✓

3

Check for any noise and loosening of fasteners found. Tighten them.

✓ ✓ ✓ ✓ ✓ ✓

Note : Actuator need to be replaced after every 2lakhs running cycle.

3.3 Control Block:

1

Check the Loosening of wire connection.

✓ ✓ ✓ ✓ ✓ ✓

Note :

Control block must be protected from external fluid liker water, mist.

During internal floor washing of coaches, system has to cover to avoid entering of water into the system.

3.4 Emergency Reset/ Mechanical Locking valve:

1

Check the Loosening of wire connection.

✓ ✓ ✓ ✓ ✓ ✓

Note :

Control block must be protected from external fluid liker water, mist.

During internal floor washing of coaches, system has to cover to avoid entering of water into the system.

3.5 Mechanical Locking Arm:

1 Checks for any major damage on ✓ ✓ ✓ ✓ ✓ ✓



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Activities

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locking pin, if yes replace it.

2

Apply grease/oil on locking pin for lubrication purpose.

✓ ✓ ✓ ✓ ✓ ✓

3.6 Power supply Connection:

1 Visually check for any damage.

Note:

Power supply must be protected from water or moist.

Must be protected from external hitting

4 Sealed Gangway (HUBNER)

4.1 Corrugated bellows, assy.

1

Visually Inspect Tears or holes in fabric

✓ ✓ ✓ ✓ ✓

2

Visually Inspect Broken bellows frame

✓ ✓ ✓ ✓ ✓

3

Visually Inspect Bellows fabric torn out of bellows frame

✓ ✓ ✓ ✓ ✓

4

Visually Inspect Sealing/gluing of screw-on frame is not tight Note : If required sealing to be renewed

✓ ✓ ✓ ✓ ✓

5

Note : In case repair is required , It has to be completed as per OEMs instructions

6

Visual inspection by flipping-up bridge plates into vertical position. Cleaning, e.g. with industrial vacuum cleaner of Dirt and garbage accumulated on corrugated bellows' floor (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

7 Visual Inspection of fasteners

✓ ✓ ✓ ✓ ✓

4.2 Bridge plate, assy. (upper)

1

Functional check by moving the flap up and down the sluggishness of rod hinge Note: Clean/lubricate the rod hinge (e.g. using oil spray)

✓ ✓ ✓ ✓ ✓

2

Visually Inspection of Upper bridge plate. Check if it does not

✓ ✓ ✓ ✓ ✓



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Activities

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rest correctly on lower bridge plate Note : Proceed with Cleaning/repair or replacement of affected component if required.

3

Visually Inspect Sliding ledge if it is worn or damaged Note : Replace sliding ledge if required

✓ ✓ ✓ ✓ ✓

4.3 Bridge plate, assy. (lower)

1

Functional check by moving the flap up and down the Sluggishness of rod hinge Note: Clean/lubricate the rod hinge (e.g. using oil spray)

✓ ✓ ✓ ✓ ✓

5 Vacuum Biotoilet (AMIT ENGINEERS)

1

Check the correct functioning toilets

✓ ✓ ✓ ✓ ✓ ✓

2

Visual inspection of the toilets (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓ ✓

3

Checking the pressure on the reducer (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

4

Checking the tightness of air connectors (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

5

Checking the tightness of water connectors (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

6

Checking the patency of the wires (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

7

Check the correct functioning of the diaphragm valves

✓ ✓

8

Cleaning the inside of the intermediate tank

✓ ✓

9

Cleaning the ejector (*) Every Alternate 6 Months (Yearly)

✓*

✓

10

Cleaning the pressure sensor and air supply lines

✓*

✓



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Activities

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(*) Every Alternate 6 Months (Yearly)

11 Cleaning the water assembly

✓

12 Cleaning the flush nozzle

✓ ✓

13 Replacing the ejector

✓

14 Replacing the pressure sensor

✓

15 Cleaning the pump

✓ ✓

16

Replacing the diaphragm and pumps spring

✓

17 Replacing the water assembly

✓

18

Check the correct functioning of the valve

✓

19 Replacing the Solenoid assembly

✓

Note :

If necessary, replace

Exchange components before the assumed period of time is accepted In justified cases (visible wear, damage, etc.)

Times between levels adopted on the assumption that the vehicle is covering approximately 170 thousand km / year

From the operational point of view, the best adapted to the cycles of maintenance of the vehicle traction

6 Water Level Indicator ( Amit Engineers)

1

Check the correct functioning of Water Level Indicator

✓ ✓ ✓ ✓ ✓ ✓

2

Visual inspection of the Water Level Indicators (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓ ✓

3 Check the wires and connection

✓*

✓ ✓

4

Checking the tightness of sensor mountings for any leakages

✓*

✓ ✓

5 Clean the sensor

✓*

✓ ✓


7 Vacuum Biotoilet ( OASIS Fabrications)

1 Clean the surface of the lavatory ✓ ✓ ✓ ✓ ✓ ✓



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Activities

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bowl/pan.

2

Check whether there is water or air leakage on western style module, Indian style module and control panel.

✓ ✓ ✓ ✓ ✓

3

Check all the hose under frame, replace them if necessary.

✓ ✓ ✓ ✓ ✓

4

Check and analyze alarming information.

✓ ✓ ✓ ✓ ✓

5

Filling recommended solutions into the lavatory bowl/pan. The liquid should cover the spray nozzles. Immerse for one hour and then clean the lavatory bowl/pan with clean water and soft brush. (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

6

Clean the lavatory bowl/pan nozzles (with copper slice) (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

7

Check the leak tightness of the discharge valve (by testing the time of pumping vacuum) (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

8

Remove the safety valve on the interim tank, repair or replace it if necessary. (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

9

Replace all the hoses and rubber joints under the coach.

✓ ✓

10

Disassemble the discharge valve completely, replace the seal components, and replace it completely if necessary.

✓ ✓

11

Disassemble the nozzles, waste pipeline fittings and water pipe fittings, and clean these components after steeping them with 4% citric acid solution for 1 hour.

✓ ✓



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Activities

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12

Check the solenoid valve, electrical switch and other parts, and replace them if necessary.

✓ ✓

13 Replace discharge valves.

✓

14

Reassemble the system, and conduct a comprehensive test according to the requirements of test program.

✓

8 Odour Control System (JADE)

1

Dispenser/Machine have to be clean inside and outside both by Micro Fiber Cloths.

✓ ✓ ✓ ✓ ✓

Note : I. When the

dispenser/machine is not in use. batteries should detach/remove from the dispenser/machine.

II. When the dispenser/machine indicates for Battery low signal. than on immediate basis Battery should change/replace.

III. Always use Alkaline 'D' Type Battery in Dispenser/Machine.

IV. Always use Consumable 600ml refill in the dispenser/machine. as 600 ml refill can fit in the dispenser/machine easily.

9 Fire Detection and Suppression System (SANROCK)

1

Visual inspection of the water cylinders for irregularities, external leaks, soiling, corrosion or similar. (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓ ✓

2

Detailed visual inspection of the WSU for irregularities, external leaks, soiling, or similar. (*) Every Alternate 6 Months (Yearly)

✓*

✓ ✓

3 Pressure testing of water cylinder

✓^

✓



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Activities

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with water with test pressure. (^) Every 2 Years

Note : Dismantling and recurrent testing of the water cylinder as per relevant Indian Standards after 10 years

10 Fire Detection And Suppression System (FOGTECH)

Note : Maintenance to be done as per Annexure II

11 Axle Mounted Disc Brake System ( KNORR BREMSE)

11.1 BRAKE CONTAINER

1

Visually examine for loose fastenings, leaks or other damage. (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓ ✓

11.2 PRESSURE TANK (75 LITRES)

1

Visually examine for loose fastenings, leaks or other damage.

✓# ✓ ✓ ✓ ✓

2 Drain condensate

✓# ✓ ✓ ✓ ✓

(#) Every 3 Months (Quaterly)

11.3 DRAIN COCK WITH NIPPLE

1

Visually examine for loose fastenings, leaks or other damage

✓# ✓ ✓ ✓

2

Operate and/or check performance as part of brake equipment system

✓# ✓ ✓ ✓


3 Renew material if required

✓


1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓



1


✓# ✓ ✓ ✓ ✓

2 Drain condensate

✓# ✓ ✓ ✓ ✓


BRAKE PANEL ACCESSORIES:

11.6 DISTRIBUTOR VALVE KE1IPKSL - WITH SUITABLE



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Activities

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RELAY VALVE & MOUNTING BRACKET

1


✓# ✓ ✓

2


✓# ✓ ✓


3

Clean the chokes & filters (*) Every Alternate 6 Months (Yearly)

✓*

4 Overhauling (OEM/RAILWAY)

✓ ✓

11.7 CHECK VALVE, RV7-T

1

Visually examine for loose fastenings, leaks or other damage (#) Every 3 Months (Quaterly)

✓# ✓ ✓

2

Operate and/or check performance as part of brake equipment system (*) Every Alternate 6 Months (Yearly)

✓* ✓


✓ ✓

11.8 COCK DH7-TE

1


✓# ✓ ✓

2


✓# ✓ ✓



✓ ✓

11.9 COCK AHB 200 NW19

1


✓# ✓ ✓

2


✓# ✓ ✓



✓ ✓

11.10 PRESSURE SWITCH MCS11/W : 1.3-1.8 BAR

1

Operate and/or check performance as part of brake equipment system (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓



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✓

11.11 TEST FITTING K1E

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.12 COCK DH7-TE

1


✓# ✓ ✓ ✓

2


✓# ✓ ✓ ✓



✓

11.13 FILTER NW19 WITH CODEPIN

1


✓# ✓ ✓

2 Clean the chokes & filters

✓# ✓ ✓



✓ ✓

11.14 PRESSURE TANK 6 LITRE (For HandBrake)

1 Visually examine for loose fastenings, leaks or other damage

✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.15 ANGLE COCK (BP)

1


✓# ✓ ✓

2


✓# ✓ ✓


3 Overhaul/Renew

✓ ✓

11.16 ANGLE COCK (FP)

1


✓# ✓ ✓

2 Operate and/or check

✓# ✓ ✓



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performance as part of brake equipment system


3 Overhaul/Renew

✓ ✓

11.17 BRAKE PIPE COUPLING(FP)

1


✓# ✓ ✓



✓ ✓

11.18 BRAKE PIPE COUPLING(BP)

1


✓# ✓ ✓



✓ ✓

11.19 INDICATOR

1


✓# ✓ ✓

2


✓# ✓ ✓



✓ ✓

11.20 ROLLER LEVER VALVE WRV-2S,G 1/4".

1


✓# ✓ ✓

2


✓# ✓ ✓



✓ ✓

11.21 FLEXIBLE HOSE WITH ADAPTOR

1


✓# ✓ ✓

2


✓# ✓ ✓



✓

4 Overhaul/Renew

✓

11.22 PRESSURE GAUGE 80x10. (BP/BC/FP)

1 Visually examine for loose

✓# ✓ ✓ ✓



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SS2

SS3

fastenings, leaks or other damage

2


✓# ✓ ✓ ✓



✓

11.23 EMERGENCY BRAKE ACCELERATOR EB3 S/L WITH BRACKET

1


✓# ✓ ✓

2


✓# ✓ ✓


3


✓*


✓ ✓

11.24 COCK G1-DN25E

1


✓# ✓ ✓ ✓

2


✓# ✓ ✓ ✓



✓

11.25 HOSE CONNECTION R1/2", 600/500 MM LONG.

1


✓# ✓ ✓ ✓



✓

11.26

BRAKE CALIPER UNIT WZ57UP10XS11 LEFT VERSION, I=2.48,FSS-NR. 1272113201.

BRAKE CALIPER UNIT WZ57UP10XS11 LEFT VER-SION, I=2.17, FSS-NR. 1267428201. Note : 1. Brake caliper rigging ratio for Power car, LSLRD and Double Decker coaches “l=2.48”. 2. Brake caliper rigging ratio for AC & Non AC coaches "l=2.17".

1


✓# ✓ ✓ ✓



Page Page 18 of 38


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SS2

SS3

2


✓# ✓ ✓ ✓



✓

11.27

BRAKE CALIPER UNIT WZ57UP10XS11 RIGHT VERSION, I=2.48, FSS-NR. 1272114201.

BRAKE CALIPER UNIT WZ57UP10XS11 RIGHT VER-SION, I=2.17, FSS-NR. 1267529201. Note : 1. Brake caliper rigging ratio for Power car, LSLRD and Double Decker coaches “l=2.48”. 2. Brake caliper rigging ratio for AC & Non AC coaches "l=2.17".

1


✓# ✓ ✓ ✓

2


✓# ✓ ✓ ✓



✓

11.28

BRAKE CALIPER UNIT WZ57UP10H16R8 LEFT VER. W. HANDBRAKE I=2.48, FSS-NR. 1267584201. Note : 1. Brake caliper rigging ratio for Power car, LSLRD and Double Decker coaches “l=2.48”. 2. Brake caliper rigging ratio for AC & Non AC coaches "l=2.17".

1


✓# ✓ ✓ ✓

2


✓# ✓ ✓ ✓



✓

11.29 BRAKE PAD 200 CM2 LEFT/RIGHT

1


✓# ✓ ✓ ✓ ✓

(#) Every 3 Months (Quaterly) To be replaced on condition basis upon reaching condeming limit

11.30 FLEXBALL CABLE ( L= 4024/2333/2197 mm).

1 Visually examine for loose

✓# ✓ ✓ ✓ ✓



Page Page 19 of 38


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SS2

SS3

fastenings, leaks or other damage

2


✓# ✓ ✓ ✓ ✓

3

Renew material if required Note: To be replaced on condition basis

✓# ✓ ✓ ✓ ✓


11.31 CONNECTING PARTS FOR FLEXBALL 125

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.32 GUARD'S EMERGENCY ISOLATING COCK

1


✓# ✓ ✓ ✓

2


✓# ✓ ✓ ✓



✓

11.33 ADOPTER

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.34 CONTROL UNIT MGS2

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.35 CONNECTOR

1


✓# ✓ ✓ ✓ ✓

2

Operate and/or check performance as part of brake

✓# ✓ ✓ ✓ ✓



Page Page 20 of 38


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equipment system


11.36 SPEED SENSOR FS01 WITH CABLE ASSY.

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.37 DUMP VALVE GV12-ESRA.

1


✓# ✓ ✓

2 Operate and check performance

✓# ✓ ✓


✓# ✓ ✓



✓ ✓

11.38 CONNECTING CABLE GV/CS

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.38 TOOTHED WHEELS (PHONIC WHEEL)

1

Visually examine for loose fastenings, leaks or other damage. (#) Every 3 Months (Quaterly)

✓# ✓ ✓ ✓ ✓

11.38 JUNCTION BOX

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


11.39 CONNECTING CABLE ASSY.

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓




Page Page 21 of 38


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SS2

SS3

11.40 DROP OUT DELAY TIME RELAY ARS TIME TRON, UC 24-240VANTISKID

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


Note : 108 Monthly to be done as per Annexure III

12 Axle Mounted Disc Brake System ( FAIVELEY TRANSPORT)

12.1 Brake Frame

1


✓# ✓ ✓ ✓ ✓


12.2 Brake Panel

1


✓# ✓ ✓


2 Overhaul

✓ ✓

12.3 Distributor Valve

1


✓# ✓ ✓

2


✓# ✓ ✓


3


✓*

4 Overhaul

✓ ✓

12.4 Air strainer for BP Air filter for FP

1


✓# ✓ ✓

2 Clean the chokes & Filters

✓# ✓ ✓


3 Overhaul

✓ ✓

12.5 Control Reservoir

1


✓# ✓ ✓

2 Drain condensate / Dust

✓# ✓ ✓



Page Page 22 of 38


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SS3


3 Overhaul

✓ ✓

12.6 Cut Out Cock for DV (A5)

1


✓# ✓ ✓


2 Overhaul

✓ ✓

12.7 Cut Out Cock A ½” , 3/4" , 3/8”

1


✓# ✓ ✓


2 Overhaul

✓ ✓

12.8 Pressure Switch

1


✓# ✓ ✓


2 Renew material

✓ ✓

12.9 Check Valve

1


✓# ✓


2


✓* ✓


3 Overhaul

✓ ✓

12.10 Relay Valve

1


✓# ✓ ✓

2


✓# ✓ ✓


3


✓* ✓

4 Overhaul

✓ ✓



Page Page 23 of 38


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12.11 Integral Volume Relay & Timing chamber

1


✓# ✓ ✓

2


✓# ✓ ✓

3 Clean the chokes & Filters

✓# ✓ ✓


4 Overhaul

✓ ✓

12.12 EP Brake Valve

1


✓# ✓ ✓

2


✓# ✓ ✓


3 Renew material

✓ ✓

12.13 Limiting Valve

1


✓# ✓ ✓

2


✓# ✓ ✓


3 Overhaul

✓ ✓

12.14 Auxiliary Reservoir & Door Reservoir

1


✓# ✓ ✓ ✓ ✓

2 Drain condensate / Dust

✓# ✓ ✓ ✓ ✓


12.15 Drain Cocks

1


✓# ✓ ✓

2


✓# ✓ ✓


3 Renew material

✓ ✓

11.16 End Cocks BP

1


✓# ✓ ✓



Page Page 24 of 38


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SS1

SS2

SS3

2


✓# ✓ ✓


3 Renew material

✓ ✓

12.17 Hose Coupling BP and FP

1


✓# ✓ ✓


2 Renew material

✓ ✓

12.18 Pilot Valve for Passenger Alarm

1


✓# ✓ ✓

2


✓# ✓ ✓


3 Overhaul

✓ ✓

12.19 BP Accelerator Valve

1


✓# ✓ ✓


✓# ✓ ✓


3


✓*

4 Overhaul

✓ ✓

12.20 Isolating Cock

1


✓# ✓ ✓

2


✓# ✓ ✓


3 Renew material

✓ ✓

12.21 Passenger Emergency alarm valve

1


✓# ✓ ✓

2


✓# ✓ ✓



Page Page 25 of 38


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SS1

SS2

SS3


3


✓*

4 Overhaul

✓ ✓

12.22 Double Brake Indicator & Single Brake Indicator

1


✓# ✓ ✓

2


✓# ✓ ✓

3 External Cleaning to be done.

✓# ✓ ✓


4 Overhaul

✓ ✓

12.23 Hose Connector for Bogie/Brake Cylinder

1


✓# ✓ ✓


2 Renew material

✓ ✓

12.24 WSP Control Unit/ WSP Control Unit Cable/ Dump Valve Connector

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓

3

Item Replacement based on Error Message

✓# ✓ ✓ ✓ ✓


12.25 Dump Valve

1


✓# ✓ ✓

2


✓# ✓ ✓

3


✓# ✓ ✓


Overhaul

✓ ✓

12.26 Speed Sensor

1


✓# ✓ ✓ ✓ ✓



Page Page 26 of 38


Activities

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SS1

SS2

SS3

2


✓# ✓ ✓ ✓ ✓

3


✓# ✓ ✓ ✓ ✓

4 Gap Measurement

✓# ✓ ✓ ✓ ✓


12.27 Phonic Wheel

1


✓# ✓ ✓ ✓ ✓


12.28 Flex ball cables

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓


12.29 Roller operated valve

1


✓# ✓ ✓

2


✓# ✓*


(*) Every Alternate 6 Months


✓ ✓

12.30

Brake caliper (drawing No. 129180F11_/F21) with brake cylinder PBAC 254-130 (Caliper ratio 2.17; right-and left-handed versions)

Brake caliper (drawing NO. 129180F31_/F41 ) with brake cylinder PBAC 254-130 (Caliper ratio 2.48 ; right- and left-handed versions)

Brake caliper (drawing No. 129180F51 ) with brake cylinder PBACM 254-130 (Caliper ratio 2.48; right-handed version and hand brake connection)

1

Test brake discs for proper functioning (brake test before bringing to use). (~) Daily

✓~ ✓ ✓ ✓ ✓ ✓

2 Visual check for exterior damage ✓ ✓ ✓ ✓ ✓

3 Check condition of brake pads

✓ ✓ ✓ ✓



Page Page 27 of 38


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4

Check clearance of brake pads in pad holders

✓ ✓ ✓

5

Check clearance between brake pads & brake disc;

✓ ✓ ✓

6

Check secure seating of mountings on the bogie. (*) Every Alternate 6 Months

✓*

✓

7

Check the pneumatic hoses and connections for leaks. (*) Every Alternate 6 Months

✓*

✓ ✓

8

Check ease of movement of the brake caliper. (*) Every Alternate 6 Months

✓*

✓

9

Check functioning of the brake cylinders. ( Can be done in conjunction with the replacement of brake pads). (*) Every Alternate 6 Months

✓*

✓

10

Remove and dismantle the brake caliper

✓

11

Clean individual components, check for damage and wear; if necessary replace

✓

12

Lubricate / grease all bearings and linkages

✓

13

Overhaul of the brake unit in accordance with the overhaul requirements of the manufacturer Replace all seals and rubber components.

✓

14

Re-assemble and install brake caliper

✓

RECOMMENDED SCHEDULE FOR MAINTENANCE ATTENTION FOR EP ASSIST EQUIPMENT

Test Box 1/2 Wiring Assembly PC

EP Coil Wiring Assembly PC

Dummy Receptacle Wiring Kit PC

EP Receptacle Wiring Kit PC

EP Plug Wiring Kit PC

Cable Assembly

Central Junction Box Assembly

End Junction Box Assembly

Test Box w/CO Assembly

Test Box Assembly



Page Page 28 of 38


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SS2

SS3

Mounting Bracket and EP Connector Kit PC

1


✓# ✓ ✓ ✓ ✓

2


✓# ✓ ✓ ✓ ✓

3


✓# ✓ ✓ ✓ ✓


Note : 108 Monthly to be done as per Annexure IV

13 Electrically Controlled Roof Opalescence Glass Unit (PRIVA LITE)

1

If rubber gave out use recommended sealant

✓ ✓ ✓ ✓ ✓ ✓

2 All wiring is in good condition.

✓*

✓ ✓

3

Framing materials are free of any damage.

✓*

✓ ✓

4

Transformer and switch are in good visible order.

✓*

✓ ✓

5

Ensure - walls, ceilings and floors are not humid.

✓*

✓ ✓


For further operation & maintenance related instructions user railways are requested to refer instruction manual of OEM in Volume – 3 of the handbook.

Caution :

Opalescence Glass unit system must be switched off at least 1 hour for every 24 hrs to enable warranty claim.

14 Seats (SUTLUJ)

1

Seats fabric should be cleaned and made free from dust using vacuum cleaner. Note : Food / Oil stains on the fabric should be dry cleaned.

✓ ✓ ✓ ✓ ✓ ✓

2

For seats with E-Leather~ : Use a basic soft brush or a vacuum to

✓ ✓ ✓ ✓ ✓ ✓



Page Page 29 of 38


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remove loose debris and wipe with a lightly moist cloth

3

For seats with E-Leather~ (Deep Cleaning)

Apply detergent spray or foam to the recommended cleaning pad (3M Ultrafine abrasive pads or equivalent) and wipe or rub the surface of the upholstery to remove any soiling. Repeat if necessary.

Next, remove the excess moisture and wipe dry with a soft cloth

If required, apply leather conditioner with a soft non-absorbent cloth.

✓ ✓ ✓ ✓ ✓

4

Snack Table should be cleaned with Mild Soap by applying it with a cloth and should be wiped with a clean cloth.

✓ ✓ ✓ ✓ ✓ ✓

5

Nuts, bolts and other fixtures should be tightened.

✓ ✓ ✓ ✓

6

Sliding cushion rollers guide should be cleaned and very small amount of grease should be applied

✓ ✓ ✓ ✓

(~)ELeather is a unique, sustainable upholstery material. It is known for its longevity without the need for frequent and invasive deep-cleaning.

15 Vacuum Biotoilet (GLOVA RAIL)

Refer to Volume-3 of the handbook for details.



Page Page 30 of 38

Annexure – I

Maintenance Activities for Single Leaf Plug Door (iFE)

Maintenance work after 5 years

S.No Activity

1 Refurbishment of solenoid valve Y1, Y2, Y3, mounted on pneumatic control board using repair kit.

2 Exchange cylinder in the lock housing mechanism

Maintenance work after 10 years

S.No Activity

1 Exchange of solenoid valve Y1, Y2, Y3, mounted on pneumatic control board using repair kit.

2 Exchange of pressure switch S15, mounted on pneumatic control board

3 Exchange rollers of roller swing arm, roller on the door leaf carrier and roller at the holding bracket on the door leaf.

4 Exchange toothed belt onto linear spindle drive unit

5 Exchange drive motor

6 Exchange spindle in spindle drive unit

7 Exchange of 98% door closed limit switch at lock housing mechanism.

8 Exchange door closed and locked limit switch at isolating lock mechanism.

9 New programming of EPROMS of electronic door control unit

10 Exchange of the NOVRAM of the door control unit

11 Exchange torsion spring of the lock housing mechanism

12 Exchange spring of the isolating lock mechanism

13 Exchange buzzer on top of the header gear.

14 Exchange limit switch "emergency device inside" at emergency egress device .

15 Exchange Magnet onto emergency egress device

16 Exchange limit switch "emergency device outside" at emergency access device

17 Exchange all door seals

18 Exchange portal seal

19 Exchange rubber bump stop at door leaf carrier

20 Exchange interior and exterior bowden cables



Page Page 31 of 38

Annexure – II

Maintenance Activities for Fire Detection and Suppression System (FOGTECH)

A. Inspection work after 1 year

S.No Component Inspection Work

1 Nozzles heads Check whether present and complete

2 Magnetic valve Check magnetic valve

Check manometer

3 Piping Check for loose screws and correct laying / attachment

4 Extinguisher module Check connectors, pressurized containers and cylinder pressure (> 160 bar)

5 Maximum temperature detectors

Function test

6 Smoke Detectors Function test

Overall system Function test of train interface

B. Inspection work after 10 years S.No Component Inspection Work

1 Extinguisher module Pressure test of pressurised containers and replace magnetic valve I

2 Piping Pressure test on piping

C. Inspection work following activation S.No Component Inspection Work

1 Piping Check for loose screws and correct laying / attachment.

Check piping system and associated components for damage caused by fire.

Blow free using compressed air.

2 Extinguisher module Replace empty pressurised containers (N2 and H2O)

Visually check connectors, other pressurised containers and cylinder pressure (> 160 bar).

3 Nozzle heads Replace the jet heads in the fire area involved


Check manometer

5 Overall system Function test

6 Affected area Clean affected area

D. Inspection work following unintentional activation S.No Component Inspection Work

1 Piping Check for loose screws and correct laying / attachment.

Check piping system and associated components for damage caused by fire.

Blow free using compressed air.



Page Page 32 of 38

Continued…..

2 Extinguisher module Replace empty pressurized containers (N2 and H2O)

Visually check connectors, other pressurized containers and cylinder pressure (> 160 bar).

3 Nozzle heads Replace the jet heads in the fire area involved


Check manometer

5 Overall system Function test

6 Affected area Clean affected area



Page Page 33 of 38

Annexure – III

Maintenance Activities for 108 monthly schedule. (KNORR BREMSE)

S.No Equipment/Sub Assy. Activity 1 BRAKE CONTAINER Visually examine for loose fastenings, leaks or other

damage 2 PRESSURE TANK (75 LITRES) Visually examine for loose fastenings, leaks or other

damage

Drain condensate 3 DRAIN COCK WITH NIPPLE Renew material if required

4 PRESSURE TANK (06 LITRES) Visually examine for loose fastenings, leaks or other damage

Operate and/or check performance as part of brake equipment. System

5 PRESSURE TANK (125 LITRES)


Drain condensate 6 BRAKE PANEL HAVING FOLLOWING ACCESSORIES: 7 DISTRIBUTOR VALVE

KE1IPKSL - WITH SUITABLE RELAY VALVE & MOUNTING BRACKET

Overhauling

8 CHECK VALVE, RV7-T Overhauling 9 COCK DH7-TE Overhauling 10 COCK AHB 200 NW19 Overhauling 11 PRESSURE SWITCH

MCS11/W : 1.3-1.8 BAR Renew material if required

12 TEST FITTING K1E Renew material if required 13 COCK DH7 Renew material if required 14 FILTER NW19 WITH

CODEPIN Renew material if required

15 PRESSURE TANK 6 LITRE (For HandBrake)


Operate and/or check performance as part of brake equipment. System

16 ANGLE COCK (BP) Renew material if required / Overhauling 17 ANGLE COCK (FP) Renew material if required / Overhauling 18 BRAKE PIPE COUPLING(FP) Renew material if required 19 BRAKE PIPE COUPLING(BP) Renew material if required 20 INDICATOR Overhauling 21 ROLLER LEVER VALVE WRV-

2S,G 1/4". Overhauling

22 FLEXIBLE HOSE WITH ADAPTOR

Renew material if required / Overhauling

23 PRESSURE GAUGE 80x10. (BP)

Renew material if required

24 PRESSURE GAUGE 80x10. (BC)




Page Page 34 of 38

25 PRESSURE GAUGE 80x10. (FP)


26 EMERGENCY BRAKE ACCELERATOR EB3 S/L WITH BRACKET

Overhauling

27 COCK G1-DN25E Renew material if required 28 HOSE CONNECTION R1/2",

600 MM LONG. Renew material if required

29 HOSE CONNECTION R1/2", 500 MM LONG.


30 BRAKE CALIPER UNIT WZ57UP10XS11 LEFT VERSION, I=2.48, FSS-NR. 1272113201.

BRAKE CALIPER UNIT WZ57UP10XS11 LEFT VER-SION, I=2.17, FSS-NR. 1267428201.

Overhauling

31 BRAKE CALIPER UNIT WZ57UP10XS11 RIGHT VERSION, I=2.48, FSS-NR. 1272114201.

BRAKE CALIPER UNIT WZ57UP10XS11 RIGHT VER-SION, I=2.17, FSS-NR. 1267529201.

Overhauling

32 BRAKE CALIPER UNIT WZ57UP10H16R8 LEFT VER. W. HANDBRAKE I=2.48, FSS-NR. 1267584201.

Overhauling

Note : 1. Brake caliper rigging ratio for Power car, LSLRD and Double Decker coaches “l=2.48”. 2. Brake caliper rigging ratio for AC & Non AC coaches "l=2.17".

33 BRAKE PAD 200 CM2 LEFT Visually examine for loose fastenings or other damage 34 BRAKE PAD 200 CM2 RIGHT Visually examine for loose fastenings or other damage 35 FLEXBALL CABLE ( L= 4024

mm). Visually examine for loose fastenings, leaks or other

damage

Operate and/or check performance as part of brake equipment System

Renew material if required 36 FLEXBALL CABLE

(L=2333mm) Visually examine for loose fastenings, leaks or other

damage


Renew material if required 37 FLEXBALL CABLE (L =

2197mm) Visually examine for loose fastenings, leaks or other

damage




Page Page 35 of 38

Renew material if required 38 CONNECTING PARTS FOR

FLEXBALL 125 Visually examine for loose fastenings, leaks or other

damage


39 GUARD'S EMERGENCY ISOLATING COCK


40 ADOPTER Visually examine for loose fastenings, leaks or other damage


41 CONTROL UNIT MGS2 Visually examine for loose fastenings, leaks or other damage


42 CONNECTOR Visually examine for loose fastenings, leaks or other damage


43 SPEED SENSOR FS01 WITH CABLE ASSY.



Renew material if required 44 DUMP VALVE GV12-ESRA. Overhauling 45 CONNECTING CABLE GV/CS Visually examine for loose fastenings, leaks or other

damage


Renew material if required 46 CONNECTING CABLE GV/CS Visually examine for loose fastenings, leaks or other

damage


Renew material if required 47 TOOTHED WHEELS

(PHONIC WHEEL) Visually examine for loose fastenings, leaks or other

damage 48 JUNCTION BOX Visually examine for loose fastenings, leaks or other

damage


49 CONNECTING CABLE ASSY. Visually examine for loose fastenings, leaks or other damage


Renew material if required 50 CONNECTING CABLE ASSY. Visually examine for loose fastenings, leaks or other

damage



Page Page 36 of 38



damage



damage


Renew material if required 53 DROP OUT DELAY TIME

RELAY ARS TIME TRON, UC 24-240V ANTISKID





Page Page 37 of 38

Annexure – IV

Maintenance Activities for 108 monthly schedule. (FAIVELEY TRANSPORT)

S.No Equipment/Sub Assy. Activity 1 Brake Frame (A0) Visually examine for loose fastenings, leaks or other

damage. 2 Brake Panel (A1) Overhaul 3 Distributor Valve (A2) Overhaul 4 Control Reservoir (A3) Overhaul 5 Air strainer for BP / Air

filter for FP (A4) Overhaul

6 Cut Out Cock for DV (A5) Overhaul 7 Cut Out Cock A ½” (A9),

3/4" (A20), 3/8” (A21) Overhaul

8 Pressure Switch (A10) Renew material 9 Check Valve (A16) Overhaul 10 Relay Valve (A17) Overhaul 11 Integral Volume Relay

(A19) & Timing chamber (A18)

Overhaul

12 EP Brake Valve (A22) Renew material 13 Limiting Valve (A23) Overhaul 14 Auxiliary Reservoir (B1) &

Door Reservoir (B7) Visually examine for loose fastenings, leaks or other

damage.

Drain condensate / Dust 15 Drain Cocks (B2) fitted to

(B1) & (B7) Renew material

16 End Cocks BP (B3 & B8) Renew material 17 Hose Coupling BP and FP

(B4 & B5) Renew material

18 Pilot Valve for Passenger Alarm (B6)

Overhaul

19 BP Accelerator Valve (B12) Overhaul 20 Isolating Cock (B13) Renew material 21 Passenger Emergency

alarm valve(B21) Overhaul

22 Double Brake Indicator(B9) & Single Brake Indicator (B18)

Overhaul

23 Hose Connector for Bogie (B10)

Renew material

24 Hose Connector for Brake Cylinder (B11)

Renew material

25 WSP Control Unit Visually examine for loose fastenings, leaks or other damage.

Operate and / or check performance as part of brake equipment System.


26 WSP Control Unit Cable

27 Dump Valve Connector



Page Page 38 of 38

28 Dump Valve Overhaul 29 Speed Sensor Visually examine for loose fastenings, leaks or other

damage.



Gap Measurement 30 Phonic Wheel Visually examine for loose fastenings, leaks or other

damage.

31 Flex ball cables Visually examine for loose fastenings, leaks or other

damage.


32 Roller operated valve Overhaul EP ASSIST EQUIPMENT 1 Mounting Bracket and

EP Connector Kit PC




2 Test Box 1 Wiring Assembly PC

3 Test Box 2 Wiring Assembly PC

4 EP Coil Wiring Assembly PC

5 Dummy Receptacle Wiring Kit PC

6 EP Receptacle Wiring Kit PC

7 EP Plug Wiring Kit PC

8 Cable Assembly - EJB1 TO CJB (PC)

9 Cable Assembly - EJB2 TO CJB (PC)

10 Central Junction Box Assembly

11 End Junction Box Assembly

12 Test Box w/CO Assembly

13 Test Box Assembly

LHB Technological Development 4. Tools and Spares


Page Page 1 of 8

4. TOOLS AND SPARES

Version : 1.00





Page Page 2 of 8



1.00 31/07/2021 First Release



Page Page 3 of 8

Content

4. TOOLS AND SPARES ............................................................................................................. 1

4.1. Axle mounted Disc Brake System (KNORR BREMSE) ........................................................... 4

4.2. Axle mounted Disc Brake System (FAIVELEY TRANSPORT) ................................................. 4

4.3. Fire Detection and Suppression (FOGTECH) ........................................................................ 6

4.4. Automatic Sliding Doors (INTERNAL) .................................................................................. 7

4.5. Electrically Controlled Roof Opalescence Glass Unit (PRIVA LITE) ...................................... 7

4.6. Vacuum Biotoilet ................................................................................................................. 7

4.7. Train Lighting Equipment .................................................................................................... 7

4.8. Pantry Equipment ................................................................................................................ 7

4.9. PUBLIC ADDRESS CUM INFORMATION SYSTEM .................................................................. 7



Page Page 4 of 8

4.1. Axle mounted Disc Brake System (KNORR BREMSE)

List of Auxiliary Consumable

S.No Consumable Specification

1 Sealant Loctite activator - 747IT (100ml)

2 Sealant Loctite 640 (250ml)

3 Sealant Loctite-222 (250ml),

4 Grease for DV & other accessories Renolint HLT2 Grease, Make: FUCHS

5 Grease for calipers OEM Specific (KB part no. – 503318)

General Tools Required

Resetting Key for Pilot Valve passenger Alarm

Quick connect coupling with Pressure Gauge for checking pressure at test points

Allen Key Set size 1.5 to 10

Socket Set (Small)

Filler Gauge of 25 Blades

Standard Pipe Wrench 12" and 18"

Hammer Wt. 800 Gm.

Mallet size 30mm

Allen Key Socket 1/2" size 5, 6, 8, 17

Allen Key socket 3/4" size 27

Deep Socket 1/2"sq. dr. size 24, 30

Nose Plier Bent (Inner& Outer)

Circlip Plier (Inner & Outer)

Screw Driver

Open Jaw Spanner size 8, 9, 10, 11, 12, 13, 16, 17, 18, 19, 20, 22, 21, 23, 24, 27, 30, 32, 41, 50

Ring Wrench size 10, 11, 12, 13, 16, 17, 18, 19, 24, 27

Socket 1/2" sq. dr. size 13, 17, 19, 22, 24, 27, 30

Ratchet Handle size 1/2"

Adjustable Spanner 0 - 30 mm ( 10 Inch)

Adjustable Spanner 0 - 43 mm ( 15 inch)

ADJUSTABLE TORQUE WRENCH 135-540 NM

ADJUSTABLE TORQUE WRENCH 50 -225 NM

TORQUE WRENCH ( 475-1015 NM )

4.2. Axle mounted Disc Brake System (FAIVELEY TRANSPORT)

List of Auxiliary Consumable


1 Sealant Loctite 577



Page Page 5 of 8

2 Grease

Molykote 33M Grease (Silicon base) or equivalent.

Rubber sliding parts, dynamic and static "O" ring internal surface contacting metal and the parts on which they slide.

Diaphragm, Seal/Threaded parts except on the Chokes.

Oxaplex H2/ Shell Rhodina RL3 Caps, main valve plugs, threaded parts

of choke.

General Tools Required

GENERAL TOOLS (For Base Depot / yard online examination / IOH Depot)

Spanner Single End A/F 6, 10, 13, 14, 19, 24, 35, 55, 60, 64

Socket Wrench across flats A/F 16 & 17, 24 & 27

Ring Spanner A/F 19 / 27 & 37

Socket Wrench across flats A/F 17, 19, 22, 27, 32 and 50

Standard Pipe Wrench 12” and 18”

Bench Vice 6”

Ball Peen Hammer 500 gm

Nylon Hammer

Chisel flat

Flat & Half round files Rough / Smooth

Screw Driver 1.2 x 4 mm x 160

Resetting Key for Pilot Valve Passenger Alarm

Adaptor with Flexible Pipe & Test Pressure Gauge for checking at test points. ADDITIONAL GENERAL TOOLS FOR PERIODIC OVERHAUL AT WORKSHOPS

Allen Key set 2 sets

Pliers 6” straight nose 2 Nos

Pliers 6” bent nose 2 Nos

Circlip pliers for internal circlip of sizes

B40 IS 3075 all light series 2 sets



Torque wrench 9.3 M Kg 2 Nos

The Special Tools and Fixtures additionally required during the overhaul of the brake equipment are covered as under in the relevant chapters. The sketches are attached in the respective equipment chapters.

FOR C3W – DV

Bench Mounting Fixture for holding C3W during overhaul - RPBF - 0018.

Special tools for overhaul under FTRTIL Part nos. - RPBF 0003, SCT 6014, SCT 6015, SCT 6092, SCT 6026, SCT 6016, SCT 6017, SCT 6093.

Extractors during dis-assembly

Hand Press



Page Page 6 of 8

Pressing Fixtures during assembly.

Special Tool for dia. 20mm Cock and Special Box Spanner.

4.3. Fire Detection and Suppression (FOGTECH)


1 Pump

Manual test pump

OEM Part No- 94000011

2 Compressor

Flushing compressor


3 Adapter


4 Wrench Wrench for Nozzle heads OEM Part No- 94000010

5 Test gas,



Page Page 7 of 8

Test gas, oil free OEM Part No - 91000087

4.4. Automatic Sliding Doors (INTERNAL) Drill Machine

Spirit level

Extension cable

Rivet Gun

Torque Wrench

Spanners

Screw Drivers

4.5. Electrically Controlled Roof Opalescence Glass Unit (PRIVA LITE) SPARE Opalescence glass

Control unit

Sealant

Cables

Transformer

SPECIAL TOOLS Sealant Gun

4.6. Vacuum Biotoilet Pipe Wrench

Spanners

Screw Driver

4.7. Train Lighting Equipment Drilling Gun

Drill Bit

Screw Driver

Cutter

Cable Connector

Multi-meter

Pliers

Contact cleaners

4.8. Pantry Equipment Spanner

Star drill bit

Drill Gun

SS Clamp

Rivet Gun

Multi-meter

Pliers

4.9. PUBLIC ADDRESS CUM INFORMATION SYSTEM Drill Gun



Page Page 8 of 8

Drill Bit

Tapping Tool

Bolt & Nut

Screws

LHB Technological Development 5. Maintenance


5. MAINTENANCE

Version : 1.00


Content in this document is compiled with the inputs provided by ICF,RCF,MCF and OEMs

LHB Technological Development 5. Maintenance




1.00 31/07/2021 First Release --

LHB Technological Development 5. Maintenance-Gangway -

IRCAMTECH/GWL/MECH/2021-22/LHB/HB/1.0 Page

Page 1 of 11

5.1. SEALED GANGWAY (HUBNER)



Page 2 of 11

Content

5.1. SEALED GANGWAY ................................................................................................... 1

5.1.1 INTRODUCTION ........................................................................................................ 3

5.1.2 TECHNICAL DATA ..................................................................................................... 3

5.1.3 PARTS DESCRIPTION ................................................................................................ 3

5.1.4 TRANSPORTATION AND STORAGE ........................................................................... 6

5.1.5 MOUNTING .............................................................................................................. 6

5.1.6 DISMOUNTING ......................................................................................................... 7

5.1.7 REPAIR ...................................................................................................................... 9



Page 3 of 11

5.1.1 INTRODUCTION The gangway is the flexible part of the train, allowing the relative movements between the wagons and offering passengers a secure and comfortable passageway.

5.1.2 TECHNICAL DATA Weight

Gangway, assy., mounting 106.8 kg 10 %

Main dimensions

Outer width approx. 1684 mm

Outer height approx. 2150 mm

Inner width approx. 1550 mm

Inner width (between floor coverings) approx. 750 mm

Materials

Corrugated bellows, assy HÜBNER bellows fabric (SEF3, grey); Aluminium profiles

Bridge plate, assy. (upper) Aluminium chequered plate; Stainless steel; PA 12 G

Bridge plate, assy. (lower) Stainless steel

Covering rubber frame, assy. EPDM

Covering rubbers, left/right EPDM

Fire behaviour Tested according to BS 6853 standard

Operating temperature The operating temperature is approx. –30 °C to +80 °C in case of normal environmental influences.

5.1.3 PARTS DESCRIPTION

Corrugated bellows, assy. The corrugated bellows (Figure-1), which is closed all around its contour, consists of flexible fabric corrugations vaulted towards the outside. The fabric corrugations are made of special bellows fabric and connected to each other by crimped-on aluminium bellows frames. The bellows frames serve the stability in shape and the fabric the flexibility of the bellows.

Two water drainage slots are punched in the outer areas of each corrugation.

Attachment to the vehicle interfaces occurs by means of screw-on frames on both sides.

Floor coverings (Figure-1, Figure-2) are located in the lower lateral area inside the corrugated bellows.

Each floor covering comprises, like the corrugated bellows, flexible fabric corrugations, which are linked by crimped-on bellows frames. The bellows frames of the floor coverings are riveted to the bellows frames of the corrugated bellows. The floor coverings cover gaps arising between the bridge plates and the corrugated bellows during train operation.

Attachment to the vehicle interfaces occurs by means of screw-on frames as well as hook-and-loop tape on both sides.



Page 4 of 11

In the lateral outer area, two retaining ropes (Figure-1, Figure-2) are attached to the corrugated bellows via eyelets on both sides. They keep the one-sided mounted corrugated

bellows in retracted position by clipping the respective snap hook into eyelets (Figure-3) on

the inner side of the bellows.

Figure- 1 Gangway, assy., mounting - front view

Bridge plate, assy. (lower) The bridge plate, assy. (lower) comprises two consoles with an adapter plate, a bent bridge plate and a rod hinge (Figure-2, Figure-3). The adapter plate with the consoles is bolted to the wagon body. The consoles support the bridge plate, which is connected to the adapter plate via the rod hinge. To avoid unwanted flipping-up of the bridge plate (e.g. by passengers), it is bolted to the consoles with countersunk screws and nuts.



Page 5 of 11

Figure- 2 Gangway, assy., mounting - rear view

The lower bridge plate serves as support for the upper bridge plate. The bridge plate can be flipped up via the rod hinge for maintenance and cleaning purposes after unscrewing from the consoles.

Bridge plate, assy. (upper) The bridge plate, assy. (upper) comprises a bent bridge plate, a rod hinge and a sliding ledge (Figure-1, Figure-3).

The rod hinge of the bridge plate is bolted to the wagon body and enables compensation of height misalignments as well as flipping-up for maintenance and cleaning purposes. The upper bridge plate rests upon the lower bridge plate in operational position and is equipped with a riveted sliding ledge on its lower edge. Thus smooth and silent movements of the bridge plates to each other are provided.

Covering rubber frame, assy. Covering rubber frames (Figure-1, Figure-3) are pulled over the screw-on frames of the corrugated bellows in order to cover their fastening screws.

Covering rubber, left/right Covering rubbers, left/right (Figure-1, Figure-3) are pulled over the screw-on frames of the



Page 6 of 11

floor coverings in order to cover their fastening screws.

Figure- 3 Gangway, assy., mounting - Floor area (sectional view from rear, exemplary)

5.1.4 TRANSPORTATION AND STORAGE

Transport There are no special shipment instructions to obey. The gangways are delivered in appropriate packaging.

Storage The gangways can remain in the packaging until mounting or can be stored on a wooden support either standing upright (mounting position) or lying on one side. The room for storage has to be dry and well ventilated.

5.1.5 MOUNTING

Preparation / Mounting information

Standard workshop equipment / standard tools required.

Suitable helping devices (e.g. crane, forklift, rope sling) have to be available.

Prior to mounting ensure that the wagon interfaces have a corresponding hole pattern.

Ensure that the wagon interfaces have a surface flatness of ± 1.5 mm/1000 mm. No steps allowed.

Mounting procedure

1. Lift the corrugated bellows with a suitable lifting device (e.g. crane, rope sling), transport it carefully to the vehicle and bring it into designated mounting position at coach-end face.



Page 7 of 11

2. Push the covering rubber frames onto both screw-on frames of the corrugated bellows.

3. Attach the corrugated bellows (Starting with lower area, continuing with lateral areas to the top. Remove lifting device from corrugated bellows’ upper area before attaching!) by bolting its screw-on frame to the wagon-end face with appropriate screw connections , for this lift covering rubber frame at screw positions. Glue the covering rubber frame in appropriate manner to the wagon-end face and apply an appropriate sealing to the screw-on frame during mounting .

4. Secure one-sided mounted corrugated bellows with retaining ropes at the wagon-end face (clip the respective snap hook into corresponding eyelet (Illustration 2 ) on the inner side of the bellows), until mounting procedure at the other vehicle proceeds.

5. Push floor coverings aside, place the lower bridge plate (flipped up to vertical position) to intended mounting position at wagon-end face where corrugated bellows is mounted, and attach its adapter plate with consoles to the wagon-end face with appropriate screw connections .

6. Push floor coverings aside and flip down lower bridge plate onto consoles.

7. Place the upper bridge plate to intended mounting position at second wagon-end face and attach its rod hinge to the wagon-end face with appropriate screw connections. Secure the bridge plate in vertical position with appropriate means.

8. Approach the vehicles and connect them with the wagon coupler.

9. Release retaining ropes from inner eyelets and expand corrugated bellows towards second wagon-end face.

10. Attach the corrugated bellows (starting with lower area, continuing with lateral areas to the top) by bolting its screw-on frame to second wagon-end face with appropriate screw connections, for this lift covering rubber frame at screw positions. Glue the covering rubber frame in appropriate manner to the wagon-end face and apply an appropriate sealing to the screw-on frame during mounting.

11. Hook snap hooks of retaining ropes into outer eyelets.

12. Push floor coverings aside and flip down upper bridge plate onto lower bridge.

13. Stick wagon-sided parts of hook-and-loop tape from floor coverings to corresponding positions at wagon-end faces.

14. Push corresponding covering rubbers onto screw-on frames of the floor coverings.

15. Attach the screw-on frames of the floor coverings to the wagon-end faces with appropriate screw connections , for this lift covering rubber frame at screw positions.

16. Fix the floor coverings to wagon-end faces with the hook-and-loop tape. 17. Check the correct mounting of the gangway and the appropriate sealing of the corrugated bellows.

5.1.6 DISMOUNTING



Page 8 of 11

Preparation / Mounting information

Suitable lifting devices (e.g. crane, fork lift, rope sling) have to be available. Procedure 1. Loosen the floor coverings from hook-and-loop tapes at the wagon-end faces on both sides.

2. Unscrew the screw-on frames of the floor coverings from the wagon-end faces on both sides, for this lift covering rubber frames at screw positions.

3. Push floor coverings aside, flip up upper bridge plate and secure it in vertical position with appropriate means.

4. Cut customer provided sealing as well as glue of screw-on frames of corrugated bellows on both sides.

5. Unscrew the screw-on frame of the corrugated bellows (starting from the top, continuing with lateral areas to the bottom) from the wagon-end face where the upper bridge plate is located, for this lift covering rubber frame at screw positions.

6. If necessary, compress and secure one-sided mounted corrugated bellows with retaining ropes at the opposite wagon-end face (clip the respective snap hook into corresponding eyelet (Figure-1) on the inner side of the bellows).

7. Unscrew the rod hinge of the upper bridge plate from the wagon-end face and remove it from gangway area.

8. Push opposite floor coverings aside, flip up lower bridge plate and secure it in vertical position with appropriate means.

9. Unscrew the adapter plate with consoles of the lower bridge plate from the wagon-end face and remove it from gangway area.

10. If necessary, separate the vehicles via the wagon coupler.

11. If necessary, release retaining ropes from inner eyelets and expand corrugated bellows in order to achieve more space for further process.

12. Unscrew the screw-on frame of the corrugated bellows in upper area from the wagon-end face, for this lift covering rubber frame at screw positions. Attach lifting device to corrugated bellows in upper area.

13. Unscrew the screw-on frame of the corrugated bellows in lateral and lower areas from the wagon-end face, for this lift covering rubber frame at screw positions. 14. Lift corrugated bellows out between wagon-end faces and deposit it at a suitable place.

15. Remove lifting device.

16. Remove residues of customer provided sealing and glue from wagon-end faces.

17. If necessary, remove hook-and-loop tapes with all residues from wagon-end faces.



Page 9 of 11

5.1.7 REPAIR

Repair of broken aluminium frames

1. Set the repair-set enclosed aluminium cross profile onto the broken profile.

2. Knock the profile into shape using the enclosed PVC hammer.

3. Drill at four suitable places holes (e.g. Ø 4.2 mm – diameter depending on profile size – refer to repair instructions of HÜBNER Repair-Set), two holes to each side of the broken profile.

4. Secure with the enclosed blind rivets.

5. Should profiles be broken in the corner area it is possible to order respective repair corners according to the serial number of the bellows.

Repair of torn-out bellows fabric

1. Slightly open the aluminium profile in the repair area using the enclosed opener pliers.

2. Re-position the bellows fabric by hand into the aluminium profile.

3. Pre-clamp the repair area every 5 cm using the enclosed crimping pliers. Pre-clamping in corner areas every 3 cm.



Page 10 of 11

4. Close the entire repair area using the special hand-closure pliers.

Repair of damaged bellows fabric (cuts, tears etc.)

1. Clean the affected area of the bellows fabric with the repair-set provided cleaning agent on the side onto which the patch will be attached.

2. Cut patches of fabric according to the size of the damaged area. Patch has to exceed size of damaged area by approximately 10 mm. Round off the edges.

3. Apply "Elastosil E 43" evenly onto the patch using a brush (approximately 2–3 mm thick).

4. Place patch onto damaged area and firmly press the patch to the bellows fabric using the enclosed cellular rubber roller. Support area from the inside with a suitable hard item (e.g. board). Avoid air bubbles.

Note: "Elastosil E 43" has to come out all around the patch edges.

5. Press the patch with a suitable helping device (e.g. wooden clamps, screw clamp etc.), possibly covering the entire repair area to the bellows fabric until the "Elastosil E 43" has hardened.

6. After hardening the glued section can be subject to strain. Note: The repaired area is after six hours firm to contact and after five days ready to be subject to strains.

7. In the roof, floor and corner area the patches should additionally be secured with the hollow rivets contained in the repair set. All patches exceeding the size of 3 x 5 cm have to be secured with hollow rivets. The riveting has to occur prior to hardening of the adhesive.

8. Let the applied adhesive dry for approximately one hour.

9. Drill out or punch holes in the bellows fabric and the patch at suitable places and according to the patch size (at a size of 3 x 5 cm use 3 hollow rivets) using a drill (∅ 4.2 mm), a hollow punch or another suitable tool.

10. Insert hollow rivets (NK 10 and NN 7). Support one side of the hollow rivet with a hard object and rivet using the PVC hammer.



Page 11 of 11

Repair of small damage of bellows fabric (e.g. detachments of silicone coating)

Small detachments of the silicone coating (maximum size: 5 mm) caused by normal operation, can be repaired according to the following repair instruction:

1. Clean the affected area of the bellows fabric with the repair-set provided cleaning agent (note the safety data sheet and manufacturer remarks of the cleaner) with the aim to completely remove dirtying by oil, grease or dust.

2. Caulk the respective area by squirting "Elastosil E 43" (note the safety data sheet) onto the affected area. If needed, the silicone can be smoothened by use of soapy water (curd soap etc.) and a plastic spatula.

3. At a relative air humidity of 50 % and a temperature of 23 °C, the silicone is hardened after 24 hours and ready to be subject to normal strains, if a layer thickness of max. 2 mm was maintained. A layer thickness larger than 2 mm requires a longer hardening time, generally the hardening time can be shortened by higher temperature and/or air humidity.

Repair of small holes of bellows fabric

Small holes (diameter 2–3 mm) of bellows fabric, caused by normal operation, can be repaired according to the following repair instruction:

1. Clean the punched area inside and outside of the bellows fabric with the repair-set provided cleaning agent (note the safety data sheet and manufacturer remarks of the cleaner) with the aim to completely remove dirtying by oil, grease or dust.

2. Caulk the hole by squirting "Elastosil E 43" (note the safety data sheet) onto the affected area so that the "Elastosil E 43" comes out on the other side of the bellows fabric. If needed, the silicone can be smoothened by use of soapy water (curd soap etc.) and a plastic spatula.

3. At a relative air humidity of 50 % and a temperature of 23 °C, the silicone is hardened after 24 hours and ready to be subject to normal strains, if a layer thickness of max. 2 mm was maintained. A layer thickness larger than 2 mm requires a longer hardening time, generally the hardening time can be shortened by higher temperature and/or air humidity.

LHB Technological Development 5. Maintenance – Plug Door


Page 1 of 17

5.2. AUTOMATIC ENTRANCE PLUG DOOR (iFE)



Page 2 of 17

Contents 5.2. AUTOMATIC ENTRANCE PLUG DOORS ................................................................................ 1

5.2.1 FUNCTIONAL OVERVIEW .................................................................................... 3

5.2.1.1 Entering the coach from outside .................................................................... 3

5.2.1.2 Activating the guard panel ............................................................................. 3

5.2.1.3 Opening doors ................................................................................................ 4

5.2.1.4 Closing doors .................................................................................................. 5

5.2.1.5 End of operation ............................................................................................. 7

5.2.2 LUBRICATION ...................................................................................................... 8

5.2.2.1 Specified Grease Type .................................................................................... 8

5.2.2.2 Initial lubrication before set-up of the vehicle ............................................... 8

5.2.2.3 Lubrication after the set-up of the vehicle ................................................... 12



Page 3 of 17

5.2.1 FUNCTIONAL OVERVIEW

5.2.1.1 Entering the coach from outside By the means of a manual unlocking device the guard can enter the door from the outside. This is possible without power in the coach.

5.2.1.2 Activating the guard panel Turning the key switch will activate the guard panel.

The inactive panel will indicate that the other panel is enabled (yellow light<) whereas all functions of the inactive panel are disabled and won’t lead to any interruption with the active panel. When all doors are closed the green loop will indicate accordingly (green lamp)

Only the doors of the active guard room will be bypassed from the green loop. This allows the guard to check if all doors of the rake are closed. The guard can then step out of his car in order to give flag signal to the loco driver.



Page 4 of 17

5.2.1.3 Opening doors In order to open the doors of one or even both sides, the according side(s) have to be

released first by pushing the release button(s) – Picture shows releasing of both sides.

Lights will indicate that the side(s) are released.

Thereafter only the released side(s) can be opened by pushing the “open all doors”

button.

After pushing “open all doors” all released doors will open accordingly.

The doors of the inactive guard room will remain closed so that there is no unwanted entering from outside possible. These guard room doors need to be opened by the inactive guard panel.



Page 5 of 17

The released signal remains active so that the inactive guard also has the chance to open his doors. Without this release signal no doors can be opened.

After pushing the “open guard room door” button, also the released door(s) in the guard room will open.

5.2.1.4 Closing doors By pushing “Close all doors” button all before opened doors will be closed.

The released signal will be eliminated hereby.

The doors of the active guard room door remain open so that the guard can step out of the train to give flag signal to the loco driver. This should only happen after the green loop signal is indicating that all doors are closed.

Also the inactive guard room doors remain open so that the guard of the inactive power car has the chance to enter the guard room even if the doors for the passengers have been closed already. These open guard doors (inactive guard room) are the reason why the green loop is not closed yet. = no green light.



Page 6 of 17

Only after the guard of the inactive guard room has closed the doors of his car by pushing the button “open/close guard door” the green loop will light up to show the active guard that all doors are closed now.

The active guard room doors remain open and are bypassed

Now as everything is OK (green loop indicated) the guard can still leave the guard room in order to give the flag signal to the loco driver to start the operation. Thereafter the guard can enter the power car again and close his doors by pushing the button “open/close guard door”.



Page 7 of 17

5.2.1.5 End of operation When all doors are closed and the green loop signal is illuminated, the guard can leave

the active power car by simply switching off the key of his panel.

After switching off the panel there will be an automatic time delayed closing (e.g. 1min) of the guard door(s). This time delay allows the guard to leave the train whereas the door automatically will close behind him. This procedure will be indicated by the door itself with a blinking light at the door.

The same time delayed closing is also possible for the inactive guard room. Therefore the guard has to press the “open/close guard door” button for more than (e.g.) 2 sec.

60

sec



Page 8 of 17

5.2.2 LUBRICATION

5.2.2.1 Specified Grease Type KLUEBER ISOFLEX LDS 18 SPECIAL A

Klueber Barrierta L 25 DL – free of silicone

5.2.2.2 Initial lubrication before set-up of the vehicle Header gear area Use grease type KLÜBER ISOFLEX LDS 18 Spezial A.

WARNING: Switch off power supply of the door system!

Guide rod (round) The guide rod have to be lubricated through the grease nipple located on the trolley with KLÜBER ISOFLEX LDS 18 Spezial A

S.No Designation

1 Guide rod

2 Grease nipple

3 Trolley

Grease amount: 4 to 6 gram

WARNING: DO NOT use hydraulic grease pistol, use hand grease pistol for greasing the ball bearing!!

Guide rail The guide rail at the top have to be lightly lubricated in the swing area with KLÜBER ISOFLEX LDS 18 Spezial A



Page 9 of 17

S.No Designation

1 Grease with Klüber Isoflex LDS 18 Spezial A,

only in the swing area!

Lock housing mechanism Following parts of the lock housing mechanism have to be lubricated with KLÜBER ISOFLEX LDS 18 Spezial A:

S.No Designation

1 Torsion spring

2 KLÜBER ISOFLEX LDS 18 Spezial A

All springs located in the lock housing mechanism



Page 10 of 17

S.No Designation

1 Latch


Latch in the lock housing mechanism

S.No Designation

1 Catch Hook


Catch hook in the lock housing mechanism



Page 11 of 17

Isolating lock mechanism for door lock Following parts of the isolating lock mechanism have to be lubricated with KLÜBER ISOFLEX LDS 18 Spezial A:

S.No Designation

1 Torsion spring


All springs in the isolating lock mechanism

S.No Designation

1 Lock lever




Page 12 of 17

Lock lever located in the door lock

Door seals All surrounding door seals, the finger protection rubber and the portal rubber must be lubricated with Klueber Barrierta L 25 DL – free of silicone.

After the finger protection rubber and the portal rubber have been greased, they need to be dried with a clean piece of cloth. 5.2.2.3 Lubrication after the set-up of the vehicle WARNING: Switch off power supply of the door system Remove old grease and dirt before applying any new lubricant.

Header gear area

Guide rod (round) The guide rod have to be lubricated through the grease nipple located on the trolley with KLÜBER ISOFLEX LDS 18 Spezial A

S.No Designation

1 Guide rod

2 Grease nipple

3 Trolley

Grease amount: 4 to 6 gram

WARNING: DO NOT use hydraulic grease pistol, use hand grease pistol for greasing the ball bearing!!

Guide rail The guide rail at the top have to be lightly lubricated in the swing area with KLÜBER ISOFLEX LDS 18 Spezial A



Page 13 of 17

S.No Designation

1 Grease with Klüber Isoflex LDS 18 Spezial A,

only in the swing area!

Drive spindle Lubricate the drive spindle over the whole length with Klüber Isoflex LDS 18 Spezial A via a small brush.

S.No Designation

1 Drive spindle

2 Grease with a brush

NOTE: After the lubrication, close and open the door approximately 3 times.

Lock housing mechanism Following parts of the lock housing mechanism have to be lubricated with KLÜBER ISOFLEX LDS 18 Spezial A

All springs located in the lock housing mechanism



Page 14 of 17

S.No Designation

1 Torsion spring


latch in the lock housing mechanism



Page 15 of 17

S.No Designation

1 Latch


Catch hook in the lock housing mechanism

S.No Designation

1 Catch Hook


Isolating lock mechanism for door lock Following parts of the isolating lock mechanism have to be lubricated with KLÜBER ISOFLEX LDS 18 Spezial A:

All springs in the isolating lock mechanism



Page 16 of 17

S.No Designation

1 Torsion spring


Lock lever located in the door lock

S.No Designation

1 Lock lever



Page 17 of 17


Door seals All surrounding door seals, the finger protection rubber and the portal rubber must be lubricated with Klueber Barrierta L 25 DL – free of silicone.

After the finger protection rubber and the portal rubber have been greased, they need to be dried with a clean piece of cloth.

LHB Technological Development 5. Maintenance – Sliding Door


Page 1 of 17

5.3. AUTOMATIC SLIDING DOOR (PARS KOMPONENTY)



Page 2 of 17

Contents 5.3. AUTOMATIC SLIDING DOORS (PARS KOMPONENTY) .......................................................... 1

5.3.1 Introduction ........................................................................................................ 3

5.3.2 Technical Description ......................................................................................... 3

5.3.2.1 Specifications .................................................................................................. 3

5.3.2.2 Mechanical part .............................................................................................. 3

5.3.2.3 Electrical system of doors ............................................................................... 5

5.3.2.4 Door control .................................................................................................... 5

5.3.2.5 Lubrication ...................................................................................................... 7

5.3.3 Assembly and adjustment .................................................................................. 8

5.3.3.1 Installation of the drive mechanism ............................................................... 8

5.3.3.2 Installation of a door leaf with accessories .................................................. 11

5.3.3.3 Wiring ........................................................................................................... 14

5.3.3.4 Adjusting the door mechanism .................................................................... 15

5.3.3.5 Installing the emergency control .................................................................. 16

5.3.3.6 Securing the door system after adjusting and before putting into operation .

...................................................................................................................... 17



Page 3 of 17

5.3.1 Introduction

Automatic sliding doors facilitates easy inter coach movement of passengers. Interior sliding doors consist of a door leaf, drive and carrier mechanism, door leaf bottom guide, bearing counterpart of the doors, electric block, and a pair of emergency disconnecting switches. The left and the right door versions are mirror-opposed. 5.3.2 Technical Description

5.3.2.1 Specifications

Internal passing (width) 810 +0/-5 mm

Internal passing (height) 1945 +0/-5 mm

Distance between door posts 860 +2,5/-2,5 mm

Opening time of the door leaf 3-5 s

Weight of the door leaf 30 kg

Weight of the carrier mechanism 18 kg

Nominal voltage 110 V DC –30 % to +30 %

Nominal current 1/2 A, max 2 A

Lifetime 30 years / 1 000 000 cycles

Safety elements. Contact tape in front-door profile Current overload detection of the motor IR sensor

5.3.2.2 Mechanical part

Door leaf: The door leaf is designed as a welded Al profile frame. This frame is then sealed with 5 mm thick safety glass with printing. An integrated handle for manual door control is a part of the frame. The front edge of the door is covered with a rubber profile with a contact strip installed.

At the top, the doors are connected via an adjustable Al console to the drive mechanism. At the bottom, the doors are guided by a pair of sliding guides. When closed, the door leaf touches a vertical strip with a rubber profile.

The door is controlled by buttons which are the part of the door leaf - one back-lit button is installed on each side of the door. Function of buttons is completed by a pair of motion sensors (1pc on each side) that register an approaching passenger and trigger motion of the door.



Page 4 of 17

Drive and carrier mechanism The drive mechanism is designed to drive and carry the door leaf. During the operation cycle, the door moves between the end positions. The door leaf runs on the ball bushing on the cut steel rod.

The mechanism is driven by a DC electric motor that moves the door leaf through the planetary gear and the motion screw. End positions of the mechanism are equipped with stops.

Closing the doors in the closed position is secured by software. If the door detects an undesirable shift from the closed position (loss of a signal on the sensor), the motor closes the door again.



Page 5 of 17

5.3.2.3 Electrical system of doors

The sliding doors are driven by a DC electric motor. The corresponding functional states (positions) of the mechanism are sensed by end-position sensors. Approximately 100 mm before the end position of the door, a second sensor is placed, which decreases the door speed during the final phase of the run.

In order to protect transported persons against shutting to the door, a contact strip at the front edge of the door leaf is installed, and overload of the electric motor is sensed. The whole system is controlled by a programmable control unit.

Control system:

Programmable control unit TIO02/AA

Power elements: Driving electrical motor 24V DC

Sensors: End-retardation activation sensor Electromechanical end switch – 2x

End-position sensor of the mechanism Electromechanical end switch – 2x

Sensor of shutting to the door Contact tape in rubber profile

Door control: Control button Buttons on door leaves

Interface door / tramway: WAGO X-COM (WAGO no. 769-151), rail-mounted terminal block DIN TS35

5.3.2.4 Door control

Basic door control In general The interior doors can be controlled either by a radar signal when the passenger



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approaches or by pressing a button on the door. Both control modes are equivalent. The system does not distinguish the difference between the button and the radar, and between the outer and inner side of the door. In case of power failure, the doors are freely movable.

Closed The doors are kept in the closed state by software. If the doors are attempted to be opened, and the cycle is triggered neither by the radar nor the button, the engine pulls the door to the closed position.

Closing / Opening After pressing the button or receiving the radar input, the door is fully opened, stays open for the set time interval, and is closed. If hitting an obstacle during closing, the door is opened again, and an attempt to close is repeated. The number of attempts is not limited. No matter a person enters the radar area or the button is pressed, the door behaves identically. If a person is in the radar space, the door stays opened.

Emergency door lay-up: After pressing the emergency control (a red switch near the door) the door is disconnected from the power supply and is freely movable. In order to return the door back to the initial state, the emergency switch has to be unlocked by turning. The door is then fully closed and operates normally.

Non-standard states During the use of the door system, where the system is in a functional, i.e. standby, non-trouble, or emergency mode, non-standard conditions may occur due to non-standard handling of the door system, which are not in accordance with the technical and the functional parameters of the equipment on which it was designed. These conditions can cause irreversible damage to the door system - mechanical or electrical parts.

Example of non-standard treatment:

Intentionally pushing / pushing into the door leaf in the opening direction, continuous or intermittent

Intentionally pulling the door leaf in the closing direction, continuous or intermittent

Any other door manipulation with the electronic door opening / closing system

As a result of the above-mentioned treatment, an excess voltage is generated in the electrical circuit of the door system control electronics, and when the electronic protective element limits are exceeded, they are damaged. Electronic protection elements and their limits (structural, functional) are appropriately sized (oversized) for standard operation. The dimensioning of these elements is specified in the relevant documentation for the TIO02 door system control unit.

As a result of the above treatment, excessive forces and influences are generated in the structure of the door system mechanism, which can increase the wear of the functional elements or damage them in such a way as to cause damage and need to perform servicing.

These findings are based on tests and measurements made on the supplied door system.



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5.3.2.5 Lubrication

Recommended lubricant types

Lubricating grease ISOFLEX 18 SPECIAL A

Dry lubricating spray with PTFE particles BERUCOAT AF 438 (BECHEM) Note :

The motion screw is forbidden to lubricate any other than the BERUCOAT AF 438 dry lubricant

The motion screw bearings have a permanent lubricating filling and do not require lubrication.

If the doors are out of order for a longer time in an aggressive humid environment, the guide rod of the travel has to be preserved by a thin layer of the ISOFLEX 18 SPECIAL A grease. Caution :

When using noted lubricants, safety instructions of manufacturers have to be observed to avoid health risks and environmental damage.

Also, instructions of manufacturers regarding the processing of lubricants have to be considered to ensure compatibility with other materials.

Before any work on the door system, the power supply of the door has to be switched off to prevent injury.

Lubrication Points Type of Lubricant

Travel bearings - ball bushings (1) ISOFLEX 18

Motion screw (2) BERUCOAT-AF438



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5.3.3 Assembly and adjustment

Only conventional tools and no special ones are required to mount the door system.

All fastening screws (bolts) have to be tightened with corresponding torques.

Immediately after the adjustment, fastening screws (bolts) of mounting parts have to be marked with the color C 2024/8140 (vermilion).

Table of torques of fastening screws (bolts)

Bolt size Torque [Nm]

M4 3.5

M5 6.8

M6 11.9

M8 29

M10 56

M12 97

M14 155

Caution :

When adjusting in the area of the mechanism - THE DANGER OF CLOSING!

All installation and adjustment of the door system must be carried out with the disconnected power!

When adjusting the door leaf with temporarily connected electrical voltage, there is no protection against closing!

Portal dimensions

The portal width: 860 +2,5 -2,5 mm

The portal height: 1945 +0 -5 mm

Difference in the diagonal size delta ≤ 4 mm

If allowed dimensions are exceeded, continuation of the installation has to be considered.

5.3.3.1 Installation of the drive mechanism

When installing, drawings and the bill of material have to be followed

Adjusting screws (eccentric) - serve to adjust an element (the drive mechanism / the



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door leaf) to the desired position

Anchor screws - serve to lock the set position (the drive mechanism / the door leaf) and finish the adjustment

Mounting the drive

The drive has to be inserted into the space above the portal (the door) and screwed (without tightening) at 4 prepared mounting points; 2 of them are adjusting (eccentric)

Adjustment (to be performed with free anchor screws only):

The mechanism has to be adjusted with the spanner to the desired position.

Then the adjustment screws have to be tightened and the anchor screws have to be tightened

The drive has to be set and adjusted with respect to the portal (in parallel and by the width) according to the drawing. Another position is not allowed

Rear View

Front View

According to the drawing, power sensors and emergency shutdown buttons have to be installed on the portal at a symmetrical distance with respect to the door entry and with a correct inclination



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Next to the drive, the power supply, the terminal block and control units have to be attached in the mounting area.

Detail of the electrical system:



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5.3.3.2 Installation of a door leaf with accessories

When installing, drawings and the bill of material have to be followed:

Mounting accessories

Bottom guide of the door leaf and a counterpart of the front seal are considered being accessories.

Bottom guide have to be attached to the floor with the supplied screws. The guide have

to be kept in position according to the drawing

Top View



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Guide require a circular rece in the floor according to the layout drawing

If necessary, washers have to be added under the guide to install the door

In the area of the portal, where the door leaf is closing, counterpart of the front seal has to be installed

Attaching to the mounting by self-tapping screws (the package), and keeping the height and symmetrical position with respect to the portal according to the drawing

Installing the door lea Adjusting screws (eccentric) - serve to adjust an element (the drive mechanism / the door leaf) to the desired position

Anchor screws - serve to lock the set position (the drive mechanism / the door leaf) and finish the adjustment

The leaf has to be slanted obliquely, slided the bottom guide, and installed in the area of the portal (door)



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The leaf has to be attached to the driving mechanism and screwed (without tightening) at 4 prepared mounting points; 2 points are adjusting (eccentric) and 2 points are anchor screws



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If necessary, the carriage can be moved manually to be out of the leaf fixing. Then, the carriage has to be moved back towards screwing

Using adjusting screws, the door leaf has to be adjusted in height and angle according to the drawing. If the door is closed, the front of the door leaf has to be positioned uniformly in the counterpart of the front seal in the whole length of the upper part and the lower part

Adjustment (to be performed with free anchor screws only):

The door leaf has to be adjusted with the spanner no. 13 to the desired position.

Then the adjustment screws have to be tightened and the anchor screws have to be tightened

Position of the door leaf has to be checked to correspond with the mounting drawing. Any collision should be eliminated in case of manual manipulation from the closing stop to the opening stop.

Any collision in the run of the door leaf with respect to the mounting has to be removed

5.3.3.3 Wiring

Wiring has to be connected according to drawings, bill of material and electrical diagrams

Wiring of the door leaf and the driving mechanism have to be installed:

The door cable has to be pulled through the power carrier, has to be inserted into the channel of the drive console and has to be extended towards the electrical system with



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the terminal block

All cables from the direction of the drive mechanism have to be connected to the electrical system according to the scheme

The power supply 110 VDC + PE has to be connected to the voltage source of the electrical system according to the diagram

Detail of the electrical system:

5.3.3.4 Adjusting the door mechanism

If the drive mechanism is correctly installed, the door leaf and accessories do not require any further adjustments. Adjustment elements of the door:

Adjusting screws of the driving mechanism

Distance washers of guides of the door leaf

Adjusting screws for connecting the door leaf to the driving mechanism The basic door adjustment consists of setting the sensed closing and opening positions inductive sensors for closing and opening (always a couple of sensors). Factory settings correspond to the drawing and the required opening width. Settings are not needed to be changed.



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Sensors can be moved in slots in the direction of closing or opening (in steps 1 to 2 mm long). Nevertheless, the spacing between the sensors in the pair has to be kept according to the drawing. Hence, the sensed block is recorded by both sensors of the pair at both end positions.

When adjusting, the distance between the sensor and the sensed block must not be changed!

When adjusting, the front of the door leaf has to be positioned to the counterpart of the front seal (by pressure) to provide a sufficient support for the door leaf in the closed position.

In order to adjust, sensor backnuts have to be loosen, the sensor has to be shifted, and backnuts have to be tightened

For a tighter closing, the closing switches have to be moved in the closing direction (in steps 1 to 2 mm long)

The changed adjustment and behavior of the door system has to be always electrically checked

After adjusting of the opening position, the carriage of the driving mechanism has to move smoothly to the end position of opening.

5.3.3.5 Installing the emergency control

After putting the door system into the operation, a test of functionality of the emergency



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control has to be performed:

In the emergency mode, the emergency shutdown button is not switched off (not pressed)

After pressing the emergency button, the button is pushed in the activated position of the emergency shutdown, the functional disconnection of the door, and the electrical disconnection of the drive to allow manual sliding

Returning the emergency shutdown button to the initial position (by turning), the door is automatically restarted to the standby state

5.3.3.6 Securing the door system after adjusting and before putting into operation

After the mechanical adjustment of all the door elements, operation of the door has to be manually tested the in the closed and open position:

Operation of the mechanism has to be manually checked across the total width (from the opening stop to the closing stop) to ensure that no collisions can appear. If a component collides and prevents the mechanism from running in the area of the drive, the collision has to be removed.

The correct adjustment of the door leaf has to be checked so that the front of the door leaf is uniformly positioned along the whole upper part and the lower part of the counterpart of the front seal after closing

After putting electrical devices into operation, a correct functionality of the door, emergency controls and protection against closing in the direction of opening and closing have to be checked again.

If the door operates correctly, the indicating light on opening and closing sensors is switched on in the direction of opening and closing. If the light is not switched on, the door has to be adjusted.

If the door does not show any defect, the following steps have to be done:

After electrical and mechanical testing of the door system , all adjusting screws can be marked with the color C 2024/8140 (vermilion)

LHB Technological Development 5. Maintenance– Hinge Door


Page 1 of 17

5.4. AUTOMATIC HINGED DOOR (BONY/IMI)



Page 2 of 17

Contents 5.4. AUTOMATIC HINGED DOORS ............................................................................................ 1

5.4.1 INTRODUCTION .................................................................................................. 3

5.4.2 System Overview ................................................................................................ 3

5.4.2.1 Pneumatic Components ................................................................................. 4

Pressure Regulator: ........................................................................................................... 4

Main Actuator Assembly: .................................................................................................. 4

Control Block: .................................................................................................................... 5

Emergency Push Button .................................................................................................... 5

Emergency Reset Valve ..................................................................................................... 6

Door Mechanical Lock Assembly ...................................................................................... 6

Mechanical Locking/Unlocking Valve ............................................................................... 7

5.4.2.2 Installation and Commissioning of Hinged door Controller ........................... 7

Main Controller ................................................................................................................. 7

Local Door Controller ........................................................................................................ 7

Mechanical Locking and Emergency Push Button Assembly .......................................... 10

Emergency Push Button Assembly ................................................................................. 11

Coach to Coach Connector Assembly: ............................................................................ 13

Ethernet Switch ............................................................................................................... 15

AC/DC to DC convertor ................................................................................................... 15



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5.4.1 INTRODUCTION Automatic door locking and opening mechanism in coach access doors is a sophisticated system in which train will only able to run from Railway station when the coach doors are in closed condition. Similarly these doors remain closed till the train stops at the next station and eliminate chances of passengers detraining from the moving train. These doors can be locally opened by pulling Emergency pulling chain and by pressing Door emergency button when train get stopped in emergency condition. All doors of one side (Left or Right depends upon platform side) of train can be opened by pressing push buttons available in door controller, will decided by guards. When the doors are open, the train should not be able to start. Controls of these doors will be available at guards/ Train crew.

Full Closed Intermediate Full Opened

5.4.2 System Overview Automatic door opening and closing mechanism mainly based on Pneumatics and Electrical. Pneumatic products are used to perform the door opening and closing operation of door. However Electrical products are to perform the control of pneumatic product to perform sequence of action.

Pneumatics System



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5.4.2.1 Pneumatic Components

By the means of a manual unlocking device the guard can enter the door from the outside. This is possible without power in the coach. Pressure Regulator: Pressure regulator required to maintain the desired input pressure in pneumatic circuit. Pressure gauge is to show the output pressure supplied by regulator. Regulating Knob adjustment to adjust the desired output pressure. Flow with regulator is Uni-directional; care must be taken during pneumatic connection. Set pressure for regulator must be 2.5 to 3bar.

Main Actuator Assembly: Main actuator assembly performs opening and closing of door. Pneumatic supply is given to actuator from both port in sequence respective opening or closing condition.Closing obstacle detection pressure switch is provided at door closing port.



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Actuator Universal joint is mechanical connected to door through hinged bracket and Locking Pin. When supply is given to Opening port of actuator, Piston rod came out form actuator and pulls to door to get open.

When supply is given to closing port of Actuator, Piston rod moves in to actuator and pulls the door to get closed.

Control Block: Control block consist of Pilot operated 5/2 Sol/Sol valve with 2 no’s flow controller at both the ports and silencers at Exhaust port. Refer below pneumatic circuit diagram. TS1, TS2 AND TS3 are the Pressure Switches. Input Supply Voltage to valve 24V DC.

Emergency Push Button Emergency push button will available at doors, one at outside of coach and one inside above the door. Door push button will be generally used by passenger in case of emergency to open the door. Emergency push button consist of 3/2 valve. One position is achieved by pressing push button and another position is achieved by supplying air to pilot port. When emergency button pressed, air supply to whole system gets cut-off. Available pressurized air in system gets release through exhaust port of emergency valve.Emergency can be pressed only when train is in stopped condition. In case emergency and train is running. Passenger has to first pull the emergency chain and wait for train to get stopped then press emergency push button.



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Emergency Reset Valve Emergency reset valve is basically a 3/2 sol/spring NC valve. Its function is to reset the pressed emergency valve or to return back the system in Automation. When valve receives an electrical signal, it connects the air supply to emergency push button pilot port to reset the emergency.

Solenoids will continuous active till train is running. So that passenger not able to press the emergency push button.

Door Mechanical Lock Assembly Door Mechanical lock assembly consist of Single acting sprung in actuator, Locking slide pin and Guide Bush. Air can be supplied to both the ports of locking actuator depending upon the door command sequence.

Basic function of Mechanical lock assembly is lock the door Mechanical when door is fully closed when door closing command received by local door controller. And unlock the door first when local door received door opening command from Guard.In case of power failure/ Pneumatic failure/Controller failure mechanical lock should get unlocked.Mechanical lock will get unlocked when pneumatic failure will happen.



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Mechanical Locking/Unlocking Valve Mechanical Locking Valve consist of 5/2 Sol/Sol valve. Basically controls the operation Mechanical door locking Arm. It connects the air to both the port of Mechanical locking actuator as per command received by Local door controller from Main controller.

5.4.2.2 Installation and Commissioning of Hinged door Controller

Main Controller Main Controller consist of HMI and Push Buttons, door can be operated from this. Installation Location: Main controller need to be installed in Generator cars, Exact Location in generator car will be as per the requirement of Indian Railway. Main controller can be screwed on any plate or frame. Panel size LXWXD - 400x400x120mm.

Local Door Controller Local Door Controller receives command from Main controller and does door operation.

Installation Location: Local door controller need to be installed on door post just above door.Initially door must be installed on door post. Door installation Process must be similar to existing door installation process. Things need to care:

Door Hinged Alignments: Door Hinged axis must be vertical and must be normal to door post Horizontal face.

Doors face parallelism in closed condition: When door is in fully closed condition door Face must be parallel to door post.

Doors bearing must be smooth



Page 8 of 17

There should not be any jerk, uneven resistance when manual opening or closing of door done.

All fasteners used to hold the door must be enough tightened, so that door should not get loosed during working. Loctite must be applied on fasteners.

Installation Steps

1. Install the fixture on door post as shown in below.

2. Insert drill guide bush in all holes. 3. Use hand drill, to do drill in all holes 4. First drilling to be done on all holes using drill bit size Ø4.2mm 5. Remove the drill guide bush from all holes. 6. Again drilling has to be done on all holes using drill bit size Ø6.8mm. 7. Again drilling has to be done on all holes using drill bit size Ø8.5mm except one hole

as shown above. 8. Tapping of M8X1.25 to be done on hole where 7 no step not applicable, size

Ø6.8mm. 9. Tapping of M10X1.5 to be done on hole, size Ø8.5mm 10. Grease to be used during tapping and drilling. 11. Tapping should be done manual not by electrical hand drill machine. 12. If tap broken on door post, it will be very difficult to do installation. Therefore

special care has to be taken.



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13. Remove the Local door controller installation fixture. 14. Fix the local door controller through fasteners M10 and M8.

15. Fix the Hinged Bracket Asm through fasteners M10. Insert the Spacers back to the bracket to maintain hinged bracket axis distance from Shell plate 68-70mm.

16. Connect the door hinged bracket with Main actuator through locking Pin. To insert

locking pin, door must be in fully opened condition. Pull out the rod from actuator till axis of main actuator universal joint and hinged bracket not get aligned. When both axes get aligned insert the pin and Lock the pin through M6 bolt.

17. Loctite to be applied on fasteners. Enough torque to be applied as per standard. 18. 18. Drills and taps need be changed when they get wear out. 19. During drilling special care to be taken that installation fixture should not get

damaged from drill. 20. Fixture for Left side door and Right side doors are different. Care must be taken

during selection of the same.



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Mechanical Locking and Emergency Push Button Assembly 1. Kept door in Open condition. 2. Install the Locking pin Installation Fixture on door guide bush.

3. Connect the air supply to door closing side of main actuator, so that door gets

closed automatically. Pressure must be in range of Operating pressure of the system 2.5 to 3bar.

4. Hold the fixture along with door until door gets closed. 5. Insert punching pin from other side to mark the centre on side wall of the door

post.

6. Remove the pin and Locking Installation fixture. 7. Drill of Ø4.0 to be done on marked punch. 8. Installed the mounting holes fixture from door side on side wall through fasteners.

9. Cut the Sealing rubbers coming between side wall and mounting holes fixture.

Aligned the Edges of fixture vertical and Horizontal. 10. Drill of Ø4 to be done on 4 holes of mounting fixture. 11. Remove Mounting Hole fixture. 12. Using Hole saw cutter-drill of size Ø36/Ø37, cut the hole in side wall of door post.

13. Install the Mechanical Locking mechanism through fasteners as shown in below

picture.



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14. Loctite on all fasteners to be applied. Enough torque to be applied as per standard. 15. Air supply to be given to both ports one by one to check the working of locking

mechanism. 16. During tightening diagonal bolts need to be tightened gradual. 17. Door to be closed through air by connecting to door closing port on main actuator.

After closing door fully, apply air to locking assembly to lock the door. 18. Try to open the door, if not opening means installation successfully done.

Emergency Push Button Assembly Holes on Body side will be available.

Mount the Emergency valve on holes as shown in below pic

Install the Emergency valve keep valve body inside the coach.

Pneumatic Connection: Refer below pneumatic circuit for tubing purpose. Use standard tube cutter to cut the tubes. Circuit shown is for one door system. Feed pipe will be available at all doors.



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Guidelines for tubing:

Sharp bends to be avoided. Wherever required, use elbow bends.

Tube cutter to be used for cutting the tube. Cutter must cut the face normal to tube axis.

Tube burrs, cuts must be removed from after cutting.

Always try to keep tubing length as lesser as possible.

After push in fit of tube with fitting bend should start after 50mm.

Brake Line Integration Steps:

Get a Tee connection from Brake pipe dia Ø20mm Metric with Ferrule Tee connector.

Extend the connection as per space availability through hard tubing.

Connect the V74G Pressure relief valve Arm.

•Add tube on other end of pressure relief valve through tubing.

Connect 2/2 Piston valve Arm

Connect Silencer on other end of 2/2 Piston valve.

Set the Pressure Relief pressure 2±0.2 bar.



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Connection must clamp so that not get broken due to vibration. Teflon must be

used at all threads. Proper tightening to be done as per standard.

Coach to Coach Connector Assembly: End wall of Coach will be provided with socket to mount the Female Connector. Mount the female connector on end wall as shown in below picture. One end of Male-Male connector assembly to be connected on one end of coach female connector and other end of male connector to be connected on other end of another coach with female connector.



Page 14 of 17

Communication Cable and Power supply Connection:



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Ethernet Switch Ethernet switch to communicate the signal from one coach to another coach as well as to all four doors PLC

AC/DC to DC convertor AC/DC to DC convertor used to create 24V DC output voltage to run our Automatic

Door System.

Input supply to Convertor will be 110 VDC from coach.

Qty. 1 convertor is used to supply 24V DC to 4 door system/Coach.



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Installation Location: Power supply and Ethernet switch location will be as per customer requirement and space availability.

Power Supply:

Ethernet switch, Local door controller, Main Controllers operating voltage 24Vdc.

AC/DC to DC convertor is used to convertor the 110 V DC to 24 V DC.

Power supply Wiring Connection:

Get the suitable length of power supply wire to connect the power supply to all electrical equipment.

Connect 110 v DC supply to Input +/- to SMPS( AC/DC convertor)

Provide 24v DC supply to Ethernet switch, Local door controller and Main controller.

As supply is DC, carefully + to be connected with positive and – with negative.

Refer wiring connection diagram as shown above.

Communication Cable Connection:

Get the suitable length communication wire to connect the communication as per electrical and communication circuit.

Ends of communication cable to be connected with RJ45 connector.

Crimping tool used for crimping of RJ45 connector must be checked and in good condition.

Connect the communication cable as per communication cable circuit.



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LHB Technological Development 5. Maintenance – Fire Alarm


Page 1 of 34

5.5. FIRE DETECTION AND SUPRESSION



Page 2 of 34

Contents 5.5. FIRE DETECTION AND SUPRESSION ..................................................................................... 1

SANROK ...................................................................................................................................... 4

5.5.1 Introduction ........................................................................................................ 4

5.5.2 Fire Detection System ........................................................................................ 5

5.5.2.1 Schematic of the Detection System. .............................................................. 5

5.5.2.2 Main Controller –CM.2.2 ................................................................................ 7

5.5.2.3 Charger Module .............................................................................................. 9

5.5.2.4 Loop MX ........................................................................................................ 13

5.5.2.5 DC DC convertor ........................................................................................... 16

5.5.2.6 Sounder Beacon ............................................................................................ 17

5.5.2.7 Fire Detectors- Ev-PP .................................................................................... 18

5.5.3 Operation ......................................................................................................... 19

5.5.4 High Pressure Water Mist Fire Suppression System ........................................ 20

5.5.4.1 Technical Description of the System ............................................................ 20

5.5.4.2 SYSTEM DESCRIPTION................................................................................... 20

5.5.5 TRANSPORT STORAGE DISPOSAL ..................................................................... 22

5.5.5.1 Transport ...................................................................................................... 22

5.5.5.2 Storage .......................................................................................................... 22

5.5.5.3 Disposal ......................................................................................................... 22

5.5.6 Mounting & Assembly ...................................................................................... 23

5.5.6.1 Mounting ...................................................................................................... 23

5.5.6.2 Assembly ....................................................................................................... 23

FOGTECH .................................................................................................................................. 24

5.5.7 Introduction ...................................................................................................... 24

5.5.8 Fire alarm system ............................................................................................. 24

5.5.8.1 Evaluation unit 1010 ..................................................................................... 24

5.5.8.2 Smoke detector series 1000 ......................................................................... 24

5.5.8.3 Maximum temperature detectors ................................................................ 25

5.5.8.4 Socket – Series 1000 detector ...................................................................... 26

5.5.8.5 Light/Audio Indicator .................................................................................... 27

5.5.8.6 Uninterruptible power supply (UPS) ............................................................ 27

5.5.8.7 Battery .......................................................................................................... 27

5.5.9 Fire fighting system .......................................................................................... 27

5.5.9.1 Pressure cylinder system .............................................................................. 28

5.5.9.2 Operation ...................................................................................................... 30

5.5.10 Installation ........................................................................................................ 30



Page 3 of 34

5.5.10.1 Transport / shipping / storage ...................................................................... 30

5.5.10.2 Installation .................................................................................................... 30

5.5.10.3 Installing the cylinder system ....................................................................... 31

5.5.11 Commissioning ............................................................................................. 34



Page 4 of 34

SANROK 5.5.1 Introduction

In order that a fire can develop, the following conditions must be present in the correct mixing ratio: - Combustible material - Energy for igniting and maintaining the fire - Oxygen (O2) An effective Fire fighting system should have the two basic sub systems.

Early detection system for Smoke and Heat

Highly reliable Suppression System

The Detection System and the Suppression system may or may not be inter connected.

DETECTION SYSTEM In order to reach an optimal level of safety for the fire protection onboard rolling stock it is essential to choose the most suitable fire detection system. The selection of system is depending on the formal requirements as well as the fire safety risk assessment which must cover all areas where there is a potential fire risk.

Regarding the risk analysis there are different risks or scenarios to consider e.g. the fire hazardous combustible material that is used in the area to be protected. The type of material, the expected igniter, humidity, air flow, air pressure etc will have an influence on the smoke, heat or flame generated which in turn gives the guidance on what kind of detection system that is required.

A Point Detection System consists of one or more redundant central unit(s) with one or more addressable communication loops on which several detectors selected depending on the risk analysis are installed.

The sensitivity and type of detector for each detection point is completely independent from the other detection points. If different products of the fire can occur, detectors sensitive to smoke, heat, flame etc can be installed in parallel or integrated in each detector. When smoke, heat or flame is generated by a fire and reaches over the defined level (or a product of several alarm criteria) an alarm is activated.

SUPPRESSION SYSTEM In order to fight a fire effectively, the above conditions have to be removed – at least in part – from the combustion process. As a rule this is achieved either by means of cooling, and therefore the removal of energy, or by reducing the oxygen that is available.

PRINCPLE OF HIGH PRESSURE WATER MIST SYSTEM The most important effects of fire fighting with water mist are the cooling and oxygen displacement effect



Page 5 of 34

COOLING EFFECT Through the atomization of water under high-pressure, the reaction surface available for the cooling process is significantly enlarged in comparison to conventional low pressure systems. As a result, fire extinguisher systems can remove energy from the fire considerably faster and more effectively. As a result of the high cooling effect, the fire is effectively fought and people and materials are protected against the effects of heat. The high cooling effect is mainly achieved by vaporization of the fine water droplets in the vicinity of the fire. This effect is supported by the shielding effect of the small droplets against heat radiation. In this way it is also possible to create effective water mist partitions (curtains) for building elements, wall openings, facades etc.

OXYGEN DISPLACEMENT Due to the high temperature levels in the immediate vicinity of the fire, the small droplets evaporate very quickly and thereby remove energy from the fire. In the neighboring areas to the fire no steam is produced by vaporization, ensuring safe evacuation of the area. As a result of the evaporation of the water in the direct vicinity of the fire its volume is increased 1640-fold, so that part of the oxygen is displaced locally at the seat of the fire. As a consequence, an inerting effect is produced at the seat of the fire, similar to that of an inert gas system.

However, in contrast to the use of inert gases, the oxygen concentration is not reduced throughout the room. In comparison to low pressure water mist systems or other conventional water fire fighting systems, the extinguishing effect is far more effective due to the small droplets used with the high-pressure technology, so that a much smaller quantity of water is required. The system pressure of 50 to 200 bar is required to create the small droplets and convey these with the required energy to the seat of the fire.

5.5.2 Fire Detection System

The fire detection system consists of 2 Nos Fire and Smoke Detectors placed suitably inside the Generator area. The Detectors are connected in a redundant loop to the control module.The Control module is connected to an Audio Visual Sounder beacon for Alarm in case of a fire.

5.5.2.1 Schematic of the Detection System.



Page 6 of 34

S.No Part Name

1 Main Control Module

2 Combined Smoke & Heat Detectors

Main Control Module

Main Control Module

S.No Part Name

1 Panel Box

2 Main Control Unit

3 DC-DC convertor 110V-27.5V and power supply

Module

4 Sound Beacon

5 Maintenance Free 7Ah 12V battery Unit



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5.5.2.2 Main Controller –CM.2.2

Controller M2.2

The Control M 2.2 is a Control Panel with a 2.2" graphical colour display used to manage and supervise a system. Control M 2.2 is equipped with communication buses for connecting to the system, and it provides the following features:

A backlit 2.2" graphical colour display

Alarm buzzer • LED status indicators • Backbone Bus Interface

Ethemet connection • RS-422/RS-485 interface (Isolated)

RS-485 interface (not isolated) • USB interface for service

Two configurable powered I/Os • Two programmable relay outputs

Nominal Supply 24 VDC

Operating Voltage Range 19-30 VDC

Current consumption (at 24V) 105 mA

Ingress protection IP20

Operating temperature range -40°C to +85°C

Weight 260g

Display 2.2”,240X320 Pixels TFT

Ethernet 10/100 Mbit, autosense

USB USB 2.0

Relays rating Max. 30V DC, 500 mA

I/O 70 (as input) 24V DC, 5-70 mA

I/O 70 (as output) 24V DC, Max. 70 mA

Cable Terminal 2.5 mm2

SD Memory Needed to save history when restarting

Setting Module is identified by physical address on the backbone bus. Address is set with 8 pole DIP switch.

Address Switch identifies modules in the system and sets the function. Control modules can serve as Bus Masters, i.e., operate in Controller Mode or in Managed Mode, for example repeaters and protocol converters. Address I and 2 are dedicated for control



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modules in Controller Mode. One control module per central shall be set in Controller Mode. If the system shall be redundant it is required to have a second control module, also set in Controller Mode. Modes for Managed and Controller are set with DIP switches as described in the following table:



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Connectons

5.5.2.3 Charger Module



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Charger Charger M provides power to the system through the Backbone Bus. It connects to either a change-over module or directly to a power supply, supervises change-over and connects the power supply units. By using dual Charger M modules, it is possible to replace one Charger M module without powering down the system.

PSU input 28 VDC

Operating voltage range 19-30 VDC

Current consumption (at 24 V battery supply only) 43 mA

Max. output current 8 A

Cable terminals 2.5 mm2

Internal NTC resistor 10 k Ohm 2%, B=3977, 3x3

Operating temperature range -40°C to +85°C (Tx)

Weight (with housing) 140g

The module is identified by a physical address on the Backbone Bus. The address is set with a 10-pole DIP switch (A). The charging characteristic can be set on the Charger M using a second DIP-switch (B).



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Address switch The DIP switch (A) value follows the binary system. The address no. can be set from I to 126 using the DIP-switch pole 1 to 7.

`

*When switch pole 10 is set to On power output 0/P is constantly active as long as Module is powered

Example 1 : One Charger M in the system = 8 + 9 OFF

Example 2: Two Charger M in the system

Charger M No.1 = 8 OFF 9 ON



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Charger M No.2 = 8 ON 9 OFF

Connections

The battery charging is automatically optimized by compensation for ambient temperature between -5°C and 40°C, when NTC is connected.

Batteries connected to the Charger M must be of the type Valve regulated lead acid batteries (AGM).

The Charger M outputs will be shut off if the battery level for any reason falls below 18VDC (+/- 0.5V).

Indicators The Charger M displays input and output status.



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5.5.2.4 Loop MX



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Loop M X enables the connection of one addressable detector loop. Two Loop M X can also be used as a redundant loop when connector together.

Operating voltage range 19-30 VDC

Voltage range loop 29-38 VDC

Current consumption (at 24 V) 55 mA

Max. output current 500 mA (< 15 minutes)

Continuous output current 250 mA

Max no. of loop units 254

Communication parameters for the detector loops

FSK keying

Cable terminals 2.5 mm2

Operating Temperature Range -40°C to +85°C(Tx)

Weight (With Housing) 140g

Address switch The DIP switch value follows the binary system. The address no. can be set from 1 to 126 using DIP-switch poles 1 to 7.



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Connections

Indicators Loop MX indicator display output and alarm status.



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5.5.2.5 DC DC convertor

Technical Data Input

Parameter Condition Data

Input Voltage Battery Voltage 24V DC

Continuous 24V DC (Nominal) : 16.8 – 33.6 VDC

t<= 0.1 s 14.4 – 16.8 VDC

No load consumption

63 mA

Stand By 35 mA

Battery Voltage 36/48/60 V DC

Continuous 48 V DC ( Nominal) 25.2 - 72 V DC

t<= 0.1 s 21.6 – 25.2 VDC



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No load consumption

34 mA

Stand By 13 mA

Battery Voltage 72/80/96/110 V DC

Continuous 110 V DC (Nominal) : 50.4 – 154 V DC

t<= 0.1 s 43.2 – 50.4 V DC

No load consumption

28 mA

Stand By 12 mA

Input Current 24 V DC 7.3 A

36/48/60 VDC 5/ 3.8/3.0 A

72/80/96/110 V DC 2.5/2.2/1.9 /1.6 A

Switching Frequency ca 70 kHz

Input Filter Two Step

Reverse Polarity Protection

With External Fuse Through Plug with coding

5.5.2.6 Sounder Beacon

Voltage: 9 - 15Vdc (12Vdc version)

18 - 28Vdc (24Vdc version)

Current: 110mA 12Vdc version (Typical Tone 5) 68mA 24Vdc version (Typical Tone 3)

Tones: 42

Volume Control 10dB

Flash Rate 1Hz

Flash Power 0.7j

Temperature: - 10°C to + 55°C

Monitoring Reverse polarity

Construction ABS/PC lens

Protection: IP54 (s) IP65 (d).

Weight: 0.33Kg



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Colour: Red or White

Lens Colour Red. Amber. Clear. Green or Blue

5.5.2.7 Fire Detectors- Ev-PP

The detector is an analogue addressable optical smoke and heat detector. The smoke and heat detector functions are independent and can be used in any required combination. The detector is equipped with a remote input & output that can be controlled individually by the system.

The detector is designed to give early warning for the presence of heat and smoke in the supervised area. The detector offers a high protection against unwanted alarms.

The low profile combined with the Omni view 360° alarm indication makes the detector suitable for sites with high architectural requirements.

The address is set by an 8-way DIP-switch.

Nominal voltage 34 V DC

Working voltage 20-38 VDC

Working current < 200μA

Alarm current < 3mA

Remote output Max 15 mA

Alarm temperature 57°C class A

Ingress protection Depending on base

Relative humidity <= 95% RH non-condensing

Temperature range -40°C to +85°C(Tx)

Weight ~ 130 g



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Connections

5.5.3 Operation

HOME SCREEN OF THE CONTROLLER

FIRE SCENARIO



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5.5.4 High Pressure Water Mist Fire Suppression System

5.5.4.1 Technical Description of the System

Characteristic Designation VALUE Unit

Temperatures:

Min. permissible temperature

+5 °C

Max. permissible temperature

+40 °C

Pressure

Propellant medium filling pressure

200 bar at 15°C

Operating pressure 200 bar

Test pressure 300 bar

Spraying Time System spraying time, operating time

4 min

Volume Volume Nitrogen Cylinder approx. 50 L

Volume Water Cylinder approx. 160 L

5.5.4.2 SYSTEM DESCRIPTION

Nitrogen Gas Cylinder



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Water Cylinder



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S.No Description

1 WATER CYLINDER WITH DIPSTICK WATER TANK CAPACITY : 80 LITRE

2 NITROGEN GAS CYLINDER CAPCITY : 50 LITRE 200 BAR

3 PRESSURE GAUGE

4 VALVE FOR NITROGEN GAS CYLINDER 250 BAR

5 SPECIAL FITTING (SUITABLE FOR GAS ACTUATION VALVE)

6 STRAIGHT CONNECTOR WITH NUT

7 HOSE PIPE SUITABLE FOR FITMENT ON ADAPTER / FITTINGS

8 END PLUS STAINLESS STEEL

9 G UNION

10 MALE STUD CONNECTOR

11 HOSE FOR INTERCONNECTION

12 FLAT JET NOZZLE ASSEMBLY

13 W-FITTING

14 T-FITTINGS

15 STAINLESS STEEL PIPE

16 CLAMP FOR NITROGEN CYLINDER

17 CLAMP FOR WATER CYLINDER

18 BACK PLATES FOR WATER CYLINDER CLAMPS

19 BACK PLATES FOR NITROGEN CYLINDER CLAMPS

20 TIE ROD FOR WATER CYLINDER

21 TIE ROD FOR NITROGEN CYLINDER

22 FLAT WASHER

24 NYLOCK NUT

25 CLAMP FOR SS TUBE

5.5.5 TRANSPORT STORAGE DISPOSAL

5.5.5.1 Transport The Nitrogen cylinder is filled with Nitrogen at 200bar, thus PRESSURISED

The water cylinders are dispatched in a filled state and are in pressure less condition.

Shock loads must be prevented due to the risk of damage to the internal coating.

All cylinders must be transported to the construction site using appropriate means of transport (e.g. cylinder trolleys) in order to prevent undesirable damage to the internal coating or the valve heads.

5.5.5.2 Storage The cylinders must be stored in a frost proof room at min. +5°C and max. 40°C and in a virtually dust-free atmosphere. Failing that, they must be protected from dust. All openings must be sealed. 5.5.5.3 Disposal



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The cylinders must be disposed of in accordance with current regulations. All cylinders must be in a pressure less state at the time of disposal. Improper usage of the cylinders must be prevented (e.g. the pressure-less cylinders must be cut up and scrapped). 5.5.6 Mounting & Assembly

5.5.6.1 Mounting The cylinders must be arranged vertically and stably and adequately safeguarded from non-permissible movement or falling over.

The cylinders must be fixed to the carrying structure by using all foreseen brackets respectively bracket holes for proper fixing of the system. The water cylinder additionally have to be supported on its bottom side.

Note: The base or the installation site must be designed for the max. operating weight. The subsurface must be dry and must not have a corrosive effect on the cylinders. 5.5.6.2 Assembly The cylinders must be appropriately mounted and connected to pipework.

Note : If there are more cylinders combined then we are talking about communication vessels. For a simultaneous draining of the water cylinders is the design of the hydraulic very important (for example: same pipe resistance of all water- or propellant cylinders).



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FOGTECH

5.5.7 Introduction Fire protection systems made by FOGTEC Rail Systems are designed to monitor locomotives, train carriages, trams and other rail borne transport systems for fire events, and if necessary initiate follow-up actions such as fire fighting.

The Generator Car is equipped with a Series 1000 fire protection system. The fire detection evaluation unit serves to inform the driver about a fire, or if temperature limits have been exceeded, and also initiates the necessary fire fighting procedures. 5.5.8 Fire alarm system

5.5.8.1 Evaluation unit 1010

AE 1010

The 1010 evaluation unit has been developed for single-channel fire-fighting with single- or dual-channel fire detection. The design of the evaluation unit allows use in a temperature range from –40°C to +85°C.

5.5.8.2 Smoke detector series 1000 The Optical Smoke Detectors Series 1000 have a moulded self-extinguishing white polycarbonate case with wind resistant smoke inlets. Nickel plated stainless steel wiper contacts connect the detector to the base. Inside the case a printed circuit board has the optical system mounted on one side and the signal processing electronics on the other.



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Smoke Detector 1101 The sensing chamber is a black moulding configured as a Iabyrinth which prevents penetration of ambient light. The Iabyrinth has a fine gauze insect-resistant cover. The chamber houses an infrared light emitting diode (LED) and a photo-diode which has an integral visible-light filter as extra protection against ambient light.

Every three seconds the LED emits a burst of collimated light, modulated at 4kHz. ln clear air, light from the LED does not fall directly on the diode because the LED is positioned at an obtuse angle to the diode.

Smoke Detector - Chamber Configuration

When smoke enters the chamber, a fraction of the collimated light is scattered onto the photo-diode. Lf the resulting signal from the photo-diode is above a preset threshold, the LED emits two more bursts of light, this time at two-second intervals. lf light is scattered onto the photo-diode by both these pulses - due to the presence of smoke- the detector signals an alarm state by switching the alarm latch on, increasing the current drawn from the supply from about 40pA to a maximum of 75mA This fall in the impedance of the detector is recognised by the control panel as an alarm signal.

The alarm current also illuminates the detector integral LED. A remote indicator connected between the L 1 IN terminal and the -R terminal will have a voltage equal to the supply voltage less 1 volt across it and so will illuminate.

To ensure correct operation of the detector the control panel must be arranged to supply a maximum of 33 volts DC and a minimum of 9 volts DC in normal operation. The supply may fall to 6 volts DC in alarm conditions if a supply current of at least 10mA is available at this voltage. To ensure effective illumination of the integral LED and any remote indicator, the supply to the detector should exceed 12 volts. To restore the detector to quiescent condition, it is necessary to expel any smoke and interrupt the electrical supply to the detector for a minimum of one second.

5.5.8.3 Maximum temperature detectors The detector head is encased in a self-extinguishing, white polycarbonate casing. Non-rusting sliding contacts connect the detector to its mount. Inside the casing there is a PCB which accommodates the signal processing electronics.



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Maximum temperature detector Onto the PCB is mounted one thermistor, which is exposed to the ambient air. As soon as the resistance of the fixed resistor reaches its preset value, an alarm is activated. The value of the fixed resistor is selected such that alarm status is reached at a specified temperature. In alarm mode, the detector triggers a semiconductor diode which increases current consumption from 50 μA to 75 mA maximum.

This drop in impedance is detected by the central controller as an alarm signal. The alarm current also switches on the integrated LED. A parallel indicator connected up between terminals L1 IN and -R is supplied with a voltage of 1 Volt below operating voltage, and when it lights up, this also signals an alarm.

To ensure that the detector operates properly, the central controller must provide a supply voltage of maximum 33 V DC and minimum 9 V DC. This supply may drop to 6 V DC in alarm mode, provided that a current of at least 10 mA remains available. The detector has to be supplied with at least 12 V DC to ensure that the parallel indicator and integrated LED light up effectively.

To reset the detector, the environment first has to be brought back to normal temperatures, and the detector then has to be disconnected from the electrical supply for at least a second.

5.5.8.4 Socket – Series 1000 detector

Standard socket - series 1000 The standard socket was designed for an easy installation of the smoke detector. The



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smoke detector can get installed and contacted by a simple clockwise rotation like all Series 1000 smoke detectors do.

The Series 1000 smoke detectors are independent from polarity. The wiring of the socket can easily be carried out through the centre notch of the socket. Additional the socket features a grounding terminal. The standard socket contains no electronic components which could get damaged during installation.

5.5.8.5 Light/Audio Indicator

Light/Audio Indicator

This IP50 rated light/audio Indicator is used to alert the guards in case of an alarm visually with three different possible colours and acoustically with a sound of 95 dB.

5.5.8.6 Uninterruptible power supply (UPS) The UPS is used to warrant that the system is working even if the power supply in the generator car for the evaluation unit 1010 is not available.

5.5.8.7 Battery

Battery for UPS

Battery is used to supply power to the fire protection system if no other power source is available and to warrant that the fire protection system is working any time it is necessary.

5.5.9 Fire fighting system The FOGTEC fire fighting system uses water to extinguish fires. The water is atomised under high pressure. The energy of this pressure is used:

To break the water up into minute droplets, providing an enormous reaction



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surface for cooling

To give the droplets enough kinetic energy to accelerate them, so that they fill the protected area with water mist.

The enormous cooling surface area of the water mist created in this way has an immediate cooling effect, which reduces heat radiated towards nearby objects and people. The water mist also evaporates in the immediate vicinity of the fire. This causes the water’s volume to expand by a multiple of approximately 1640, which displaces oxygen locally (rendering it inert), but without reducing oxygen levels so much that it would endanger people. Fire is suffocated right at the flames. Soot particles in the smoke are bound to the water mist, and water-soluble smoke components are washed out.

The water vapour in the air binds soot particles in the smoke, which reduces smoke damage and the risk of smoke poisoning. Dangerous combustion gases can also be washed out. Generally speaking, using water mist has the following benefits:

The extinguishing medium does not endanger people.

People and nearby areas are protected against radiant heat.

A minimal amount of water is used.

The source of the fire is quickly contained.

Low downtimes.

Little space required for installation.

5.5.9.1 Pressure cylinder system The fire fighting module has been designed to accommodate the largest possible amount of extinguishing agent into the smallest possible space. The fire fighting module consists of one 20 litre nitrogen cylinder and one 50 litre water cylinder filled with demineralised water as an extinguishing agent. The system is activated via a 24VDC magnetic valve on the nitrogen cylinder. When the FOGTEC system is activated, water is pushed out of the water tank towards the jets by propellant expanding into the piping system. The nitrogen tank is filled with nitrogen at 200 bar as a propellant. The water containers are under atmospheric pressure. In the event of a leak which causes the pressure to drop to less than 160 bar, the aforementioned pressure switch reports a fault to the evaluation unit. The storage tanks are connected up via the magnetic valves and water adaptors by means of high-pressure tubing.

The pressurised containers are installed upright position. Because of this, a special rise-pipe has been built for the extinguishing agent tank in order to facilitate vertical installation.

H2O cylinder

H2O cylinder



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Nitrogen cylinder

Nitrogen cylinder

Nozzle DK 4-11

Nozzles DK 4-11

This nozzle is used for deluge systems. It requires a system with manual, electric or pneumatic activation. As soon as the system is activated, water mist is discharged. Optional protective Teflon caps prevent passing contamination inside the nozzle.

Manual activation button The manual activation button is a simple red button, which is positioned in the driver’s cab, near to the door to the engine room. If it is pressed manually, an alarm signal is sent to the evaluation unit, which activates the fire fighting system.

Manual activation button



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Piping Only high-pressure stainless steel piping may be used if the FOGTEC fire fighting system is to operate properly. This prevents corrosion and ensures that the system functions without impairment. Stainless steel piping can be connected up by welding or by means of suitable screw-connectors. The connecting elements must be made of the same material as the piping itself.

5.5.9.2 Operation In the operation of these vehicles, the vehicle driver is responsible for ensuring that the fire alarm system is operational and fault-free. The system status can be seen in the guards’ compartment on the evaluation unit’s LED array. The human-machine interface must not show any faults to the operator while the vehicle is operating. A generator car may only operate while a fault is showing if the vehicle operator allows this for a given route. In such cases the remedial measures specified by the vehicle manufacturer and operator for the vehicle come into play.

5.5.10 Installation

5.5.10.1 Transport / shipping / storage All components must be stored dry and at room temperature. Prior to transport, components must be packed so that they are protected against foreign objects and against damage by other parts.

protective transport caps for storage, transport and installation.

Protective transport caps 5.5.10.2 Installation Installation may only be done by trained personnel as stipulated in DIN VDE 0105 or IEC

364.

The components must not exhibit any damage.

Tubes and piping should be fitted such that they are not under strain and not twisted. The installation guidelines provided by the manufacturer (of the tubes and piping) applying to these components must be observed.

Fit cables and tubes in a way which avoids rubbing, kinking, and bend-radii that are too small.

Equipment should always be fitted so that enough space is left to operate and remove



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it.

Maintain any torque levels specified for installation.

Observe installation directions, where necessary, when fitting (for example: embossed arrow on some equipment).

Ensure a high level of cleanliness when installing; no particles whatsoever may find their way into the extinguishing agents, into the jets, into the piping, into the smoke detectors and so on. Inspect every component for damage before fitting it.

Check the inside of tubes, pipes, fittings and so on before fitting to ensure that they are clean, and clean them if necessary.

The water and nitrogen containers should be checked visually for leakages before installation (manometer approx. 200 bar +/- 20 bar at approx. 20 °C, no moisture caused by escaping extinguishing agent).

Electrical installation must be done in compliance with the relevant directives.

5.5.10.3 Installing the cylinder system

Pre-fitting to the water containers

Fit the water cylinders securely.

Remove transport cap.

Remove the two stoppers on the water adaptor. Before removing them, ensure the cylinders are upright, otherwise the extinguishing agent will escape.

Fit the enclosed rupture disc adapter such that the lasered-on disc points towards the inside of the cylinder. When you fit it, make sure that this disc is not already damaged, and that it does not get damaged while you are fitting it. The rupture disc adapter is fitted at the outlet of the cylinder system into the piping system. This component prevents the extinguishing agent from evaporating.

Sealing stopper

Burst disc adapter



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The electrical components are installed in compliance with the circuit diagram. When you install them, take care to preserve the relevant IP protection level. Use cables whose diameters and designs are suitable for the consumers and comply with fire protection regulations.

Installing the piping

The precision steel piping must be compliant with DIN 2391, Part 1 (AISI 316 TI) (material: 1.4571 stainless steel).

To connect the piping, use cutting ring screw connectors, or press-fittings suitable for the pressures involved (200 bar during operation, 300 bar test pressure).

Before installation, check that every section of piping is clean and free of cutting oil.

Check that all the ends of the pipes are clean and undamaged. Drilled holes and pipe-ends must be de-burred.

Fit the piping along its entire length using pipe fittings attached to fixed points.

When you choose your pipe mountings, remember that the piping will expand when hot and contract when cold.

Choose spacing A (A = middle of pipe clip to middle of next pipe clip (see Fig. 17)) in accordance with the dimensions of the piping.

Elongation in areas around bends may not be obstructed by other pipes.

The bend radius may not be any further than 300 mm away from the mounting or screw-fitting.

Pipe mountings may only be fitted to fixed objects.

Pipe connectors must be made of stainless steel (AISI 316 Ti) and fitted in compliance with the manufacturer’s specifications. Cutting oils, lubricants, and thread sealing agents such as P.T.F.E, adhesive tape and hemp may not be used.

Straight piping Bent piping

Exterior diameter of pipe [mm] Spacing A between pipe attachment elements [m]

6.0 - 12.7 1

The following points should also be observed:

Ensure that connection points are accessible:

Components that require regular maintenance (such as jets, extinguishing agent containers) have to be accessible.



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Ensure that piping system is routed clearly:

Right-angles, parallel, clear.

Make sure the overall impression is a clean one. This facilitates quick troubleshooting, easy maintenance and simple repairs.

Utilise suitable mountings and pipe clips.

Use suitable, commonly available fitting tools.

Never connect pipes directly to each other.

Install piping so that it is not under tension.

Take into account potential elongation.

Never attach pipe clips too near to bends in the pipe.

Avoid short pieces of piping.

Short pieces of pipe are susceptible to breaking.

Use combined screw-in connectors instead of short pieces of piping.

Ensure that the forces exerted by installed components (such as ball valves) are absorbed by means of secure attachments.

Pressure test Pressure testing is done once the entire piping system has been installed. Sections and modules that do not permit full access to their piping during this process are subjected to pressure testing by subcontractors beforehand.

Pressure testing has to be done on piping and tubes. Installed components such as switches and sensors do not have to be put under pressure; but their openings have to be closed, pressure-tight, before or after the sensors are installed.

Please refer to the component descriptions and system documentation for maximum permitted pressures on the various components.

Pressure test procedure:

Close any pipe-ends that are open.

Fit a dummy plug into every jet holder.

Connect the pressure device to the piping.

Connect the water tank to the pressure pump, after filling it with clean, particle-free drinking water.

Fill the piping completely with water.

Remove the water supply (if possible).

Apply a pressure of 300 bar to the piping using the testing equipment.

Keep this pressure applied to the piping for two hours by closing off the ball valve on the test pressure pump.

If the pressure drops in the closed system, look for the place where it is leaking and fix it. After that, repeat the final stages again.

Following successful pressure testing, release the pressure from the piping and detach the pressure pump, as well as any dummy plugs and dummy jet inserts. You should flush out the piping straight after pressure testing.

Write a pressure test report. Flushing process

Clean out the piping mechanically before commissioning the system.

The flushing water has to be able to drain out from every part of the system in order to



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prevent water damage. It is especially important to check this in dry rooms and rooms containing electrical installations.

Connect the flushing system to the piping.

Flush the pipes with water.

Ideally, flush with water then blow out with compressed air.

A permanent flow of water should also pass through any cross-pieces in the piping.

Flush every section of piping for approximately 15 minutes.

Test the purity of the piping.

No more particles or dirt should be left in the piping.

Detach the flushing device.

Empty all of the piping after the flushing process, and close the holders.

Connect a tube firmly to the piping.

Blow compressed air into the piping system until it is dry.

Write a report on the flushing of the piping. 5.5.11 Commissioning

The fire protection system should be commissioned in compliance with the commissioning protocol and the maintenance log.

Before commissioning, and before the associated serial testing of the system, the system first has to Furthermore, any electrical connections required to operate the extinguishing agent container system must first be made. However, voltage for operating the system should not yet be applied (e.g. remove fuse).

Once the basic conditions are in place, function testing is performed as part of commissioning be installed ready for operation, flushed, and pressure-tested.

The following stages belong to commissioning:

Switch the entire system to ‘No voltage’.

Remove the solenoid by undoing the knurled screw in front of the gas valve on the nitrogen cylinder.

Turn on the power supply for the whole system.

Check the solenoid in front of the gas valve belonging to the nitrogen cylinder to see whether it is producing a magnetic field (e.g. using a screwdriver).

Test the pressure in the nitrogen cylinder.

Check that all the jets are present.

Switch the entire system to ‘No voltage’.

Attach the solenoids to the valves belonging to the nitrogen cylinders.

Turn on the power supply for the whole system.

LHB Technological Development 5. Maintenance –Smart Coach


Page 1 of 21

5.6. SMART COACH



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Contents 5.6. SMART COACH .................................................................................................................... 1

5.6.1 Introduction ........................................................................................................ 3

5.6.2 Passenger Information and Coach Computing Unit (PICCU) ............................. 3

5.6.3 Operational Procedure of PICCU ........................................................................ 3

5.6.3.1 PAPIS (Passenger announcement/ passenger information system) .............. 3

5.6.3.2 Route Selection Process ................................................................................. 5

5.6.3.3 Coach ID & Coach AbbreviationsSetting ........................................................ 5

5.6.3.4 On/Off Announcement Time set / Control Scroll Speed ................................ 6

5.6.3.5 Upload Database ............................................................................................ 7

5.6.4 Microcontroller Based Smart Switch Board Cabinet (MSSBC) ........................... 7

5.6.5 Fire System ......................................................................................................... 8

5.6.6 Camera ............................................................................................................... 9

5.6.7 Analytics ............................................................................................................. 9

5.6.8 Water level Check............................................................................................. 10

5.6.9 Integration with WSPD ..................................................................................... 11

5.6.10 Energy Meter .................................................................................................... 12

5.6.11 Air Sensor ......................................................................................................... 12

5.6.12 TASI Sensor ....................................................................................................... 14

5.6.13 ETU ................................................................................................................... 16

5.6.14 GPS Server ........................................................................................................ 20

5.6.15 GSM Test .......................................................................................................... 20

5.6.16 Infotainment..................................................................................................... 21



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5.6.1 Introduction

The “Optitech” On Board System” is an integrated solution for PassengerInformation System and surveillance applications. System uses an IP all video components (LCD displays and IP cameras) and Multi-Drop RS485data link and Analog Audio Signal lines for audio distribution. In this sense it is a Hybrid system, in which the two systems work complementary andredundant to each other depending on their level of availability. Thissignificantly raises the system's availability in the event of a network breakdownon either link.

Amplifier System It supports TCP/IP network for all video communications on the network.

For Audio Lines, a Balanced Line Distributed Amplifier System isprovided 5.6.2 Passenger Information and Coach Computing Unit (PICCU)

The PICCU is the heart of the system to which all peripherals connect toachieve integrated system level functionality. PICCU is an industrial gradecomputer system

5.6.3 Operational Procedure of PICCU

5.6.3.1 PAPIS (Passenger announcement/ passenger information system) The system operates on GPS and manual triggers to automatically generate a wide range of automatic alerts relevant to passengers and train operating staff. It gives information about //train location//next halting station//late running status of train//Weather Information// Toilet Occupancy status. When the system is powered it shows a screen that is called Home screen.

1 2 3

4 5 6 7 8 9



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1. Air Sensor :

CO2, VOC, Humidity, PM10 and PM2.5 sensors for air quality.

Automatically detect the cleaning requirements for air filters

Measurement of Choked Filters to aid in HVAC 2. GPS Server :

It can be checked by checking lat., long. and date & time. 3. Energy :

It shows power and current consumption of motor. 4. RMPU:

To check status of (HVAC/AC Plant) & Inside Coachtemperature. 5. CVVRS :

To configure & check live view of the CCTV

Video extraction can be done. 6. WSPD:

Monitored covered distance, all wheel axle data and track condition data. 7. TASI :

Toilet announcement

Status of latch detection and panic alert

Toilet odour and Ventilation fan 8. System:

Functions of volume control jog dial

Status of GSM 9. APIS :

Selection of Route

Database Updation

Information about train location

Next halting station andLate running status of train 10. Analytics :

Capturing, and identifying a person from a digital image or a video frame 11. Fire System :

Fire alarm

Action alert

10 11



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5.6.3.2 Route Selection Process To select a route click/touch on the icon having train image

Click on “Route selection icon” to enter into the menu

Select the route or enter the route which is required to start.

Click on “YES” or “NO” to confirm your selection

In between the route play, route change option is also available

Click on Change Route, Select the new route, and confirm the selection

These are pre-recorded messages, Click on any message and audio voice will be heard for the selection and next haulting station.

5.6.3.3 Coach ID & Coach AbbreviationsSetting To set coach abbreviations.

First enter the APIS menu on the Home Screen.

Click on settings. & enter password “1234”



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Set CCA (Coach Commercial Abbreviation) as per thecoach. To Set Coach ID

First enter in the APIS Manager Menu, then IPMenu.

Set Coach ID as per the coach.

Click on Save. 5.6.3.4 On/Off Announcement Time set / Control Scroll Speed To set Announcement ON and OFF time.

Enter in the APIS Menu. Go in settings.

Enter password “1234” .click on Miscellaneous.

Set time for ON announcement /OFF Announcement.



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Choose scroll speed by drop down option. 5.6.3.5 Upload Database To set Announcement ON and OFF time

Enter in the APIS Menu. Go in settings.

Enter password “1234” .Insert Pen drive & Click on upload.

After process click on the Save tab.

5.6.4 Microcontroller Based Smart Switch Board Cabinet (MSSBC) MSSBC (Microcontroller Based Smart Switch Board Cabinet) is a device use to control/monitor the device connected in the switch Board cabinet like Water pump, light control, AC control, energy consumption in a coach etc & interface with PICCU on ethernet so that MSSBC can provide all the data to PICCU.

MSSBC - The monitoring of water pumps.

Below screen shows the diagram of the monitoring of the water pump



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Click on Pump Status to check the water level, fault status of the pump

Water Pump/SBC Integration

5.6.5 Fire System Fire & smoke system installed in the smart coach to alert the passengers & staffabout the fire. This system integrates with PICCU for providing the message ofemergency evacuation of the coach. Check the status of the system by a click on the(Fire System) icon.

Click on the (Fire System)and check the status of the Fire Detection System.



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5.6.6 Camera The PICCU also acts as an Network Video recorder for CCTV surveillance on thecoaches. The IP-CCTV system is achieved by the NVR software service. Click on the camera icon. It shows

Status of all six cameras.

Camera recording working or not working.

Camera monitoring option like 1:1, 1:2, 2:2, 3:3.

(<) (>) To go on forward or backward

To refresh the camera status option

Export tab to export the desired portion of the recording in external storage devicelike pen drive.

Setting Tab to add the camera frame rate setting audio recording setting etc.

5.6.7 Analytics CCTV Analytics module (facial recognition system) is capable of capturing, and identifying a person from a digital image or a video frame.



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Click on Analytics app

Click on the face gallery to see the saved face.

Blacklist a particular person and check the alert .

Click on Blacklist.

Click on Save.

Click on Back.

If Blacklisted person detects on camera, an alert will be generated. Check generated alert in Alert window.

5.6.8 Water level Check The system consists of a water level sensor in each coach to monitor the water levels inside the coach.

If water level falls below threshold values, the system generates automatic notification/alert to the maintenance staff at the next upcoming station.

To check water level Click on system icon.

Screen will show the water level.



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Water level indication should be Low, Medium & Full.

Message received on registered Cell phone no & Email address

5.6.9 Integration with WSPD It shows total covered distance, all wheel axle data and track condition data.

To check WSPD first click on



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5.6.10 Energy Meter Power and current consumption of motor, measurement capabilities required to monitor an electrical installation.

To check energy click on

It shows power factor and active power

5.6.11 Air Sensor CO2, VOC, Humidity, PM10 and PM2.5 sensors for air quality measurement have been provided in the coaches. Choked Filter to aid in HVAC maintenance are provided to automatically detect the cleaning requirements for air filters. Power and current consumption of motor, measurement capabilities required to monitor an electrical installation.

Set Threshold value are given below.

Description Range Status

PM10 0-150 GOOD

>150 BAD

PM2.5 0-150 GOOD

>150 BAD

CO2 0-2000 GOOD

>2000 BAD

VOC 0-3000 GOOD

>3000 BAD

To check Air Quality Index click on

Click on the Air Sensor Icon.

Click on the appropriate tab to check the graph of sensors.



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Click on Sensors Reading to Check Values

To check the Choked filter sensor. Set Threshold values are given below.

Description Range Status 1 0-150 Choked

2 >150 Not choked

Click on the Air Sensor Icon.

Click on Sensors Reading to Check Values

Check value



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5.6.12 TASI Sensor TASI unit collects the data from all the above sensors over RS485 and DALI interfaces provided on the unit and sends the data to PICCU over RS485.

The unit takes feedback from the Latch detection system to indicate toilet occupancy and play toilet etiquettes announcement in English and Hindi for the passengers. The unit also creates a Panic alarm in case Panic Alarm Button is being pressed by the passenger stuck in the lavatory needing help. To check Toilet odour sensor

Click on the TASI icon at PICCU screen.

Click on the Sensor Icon.

Sr. no. Range Toilet odour

1 0-5 Good

2 5-20 partially good

3 20 Bad

To check Ventilation Fan Sensor


Click on the Sensor Icon.



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Threshold value of VFS given below

Sr. no. Range VFS status

1 0-5 Fan OFF

2 5-1000 Fan ON

Check Status- OK

Check Status- NOT OK

To check Lavatory Sensor To check the Lavatory sensor click on the TASI icon at PICCU screen.

Click on Lavatory icon and

Check status -Choked/Operational/Leaking



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Working Details- Water Trap - Wet/Dry

Water Curtain - Wet/Dry

To check Latch Detection To check the status of Latch detection of toilet,


Case 1. Close the Door of Toilet.

Check status –Occupied NOTE: Toilet etiquettes announcement will start after latch detection

Case 2.- Open the Door of Toilet. Check status –Vacant

To check Emergency Push Button

Press Emergency Push Button in case of emergency.


Alert icon will start blinking in red color.

Panic alert sounds will come on the Non Ac area speaker

5.6.13 ETU To reduce chain pulling and provide quicker emergency services to the passenger, Emergency Talk Back Systems in every coach is also provided to allow the Train Supervisor/ nominated person to talk to the passenger via the Ethernet Train Backbone and Intercom lines.

Click on alert icon to go in the menu

Shows the call status or notification of ETU (EMERGENCY TALK-BACK UNIT)

To check Emergency talkback unit (ETU)

DEFAULT SCREEN OF SLAVE ETU

Slave ETU Led indication- LED (RED)- OFF

LED (GREEN)- OFF

LED (YELLOW)- ON

Master screen at Default condition



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Slave PICCU Default screen-

Hold the push button for 3 sec to make a call. Slave ETB Led indication-

LED (RED)-Blink

LED (GREEN)-OFF

LED (YELLOW)-Blink

Master screen –

Indication of call, shows at master screen. PICCU Slave screen-

LAMP ON & OK status Checkbox is ✓



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Slave ETB Led indication- LED (RED)-ON

LED (GREEN)-OFF

LED (YELLOW)-ON

Master screen-

Click Answer bar to answer the call

PICCU Slave screen-

Ringing & ON checkbox is ✓.When call is placed.

Ringing Bell will be heard. Slave ETB Led indication-

LED (RED)-ON

LED (GREEN)-ON

LED (YELLOW)-ON



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Master screen-

Answer bar is disabled after answering the call.

PICCU Slave screen-

At the time of call processing, ONLINE & REC status Checkbox is✓

Communication with both ETB can be done now. Slave ETB Led indication-

LED (RED)-OFF

LED (GREEN)-OFF

LED (YELLOW)-OFF

Master screen –

After answering the call, call disconnect bar is enabled to cut the call.

PICCU Slave screen-

After click on call disconnect bar screen TERMINATE bar is ✓

When call disconnected TERMINATED call checkbox is ✓



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NOTE: Default screen will appear after Termination of call.

5.6.14 GPS Server To check GPS server

Connect antenna.

Click on GPS Server.

Check GPS Server app lat long should be displayed on screen with date and time.

5.6.15 GSM Test Connect Sim & antenna.

Click on System.

Check , IP should be assigned to GSM modem.



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5.6.16 Infotainment First download the optiplay application on the phone from play store or iTunes store for android & windows.

Connect your phone to the server network.

Open application

Login PAGE

Enter your phone number.

Click on register to get access of the application.

LHB Technological Development 5. Maintenance -Amenities


Page 1 of 31

5.7. AMENITIES



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Contents 5.7. AMENITIES ........................................................................................................................... 1

5.7.1 VACUUM EVACUATION SYSTEM ........................................................................ 3

AMIT ENGINEERS .............................................................................................................. 3

5.7.1.1 Introduction .................................................................................................... 3

5.7.1.2 Working .......................................................................................................... 3

5.7.1.3 Components ................................................................................................... 5

5.7.1.4 Interface Requirements .................................................................................. 7

OASIS FABRICATION .......................................................................................................... 7

5.7.1.5 Introduction .................................................................................................... 7

5.7.1.6 Specification ................................................................................................... 7

5.7.1.7 Components ................................................................................................... 8

5.7.2 WATER LEVEL INDICATOR ................................................................................ 12

AMIT ENGINEERS ............................................................................................................ 12

5.7.2.1 Introduction .................................................................................................. 12

5.7.2.2 Components ................................................................................................. 13

5.7.2.3 Operation ...................................................................................................... 13

5.7.2.4 Installation .................................................................................................... 14

5.7.3 CHILD PROTECTION SEAT ................................................................................. 17

EURONICS ........................................................................................................................ 17

5.7.3.1 Introduction .................................................................................................. 17

5.7.3.2 Parts and hardware ...................................................................................... 17

5.7.3.3 Installation .................................................................................................... 17

5.7.3.4 Method of Usage .......................................................................................... 18

5.7.4 PASSENGER INFORMATION SYSTEM ................................................................ 18

ARECA .............................................................................................................................. 18

5.7.4.1 Introduction .................................................................................................. 18

5.7.4.2 Components ................................................................................................. 18

5.7.4.3 Installation .................................................................................................... 19

5.7.5 INFOTAINMENT SYSTEM .................................................................................. 22

FUNTORO ........................................................................................................................ 22

5.7.5.1 System Overview .......................................................................................... 22

5.7.5.2 Monitor Installation ...................................................................................... 25

5.7.5.3 G Mouse Installation..................................................................................... 31

5.7.5.4 3G Router Installation ................................................................................... 31



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5.7.1 VACUUM EVACUATION SYSTEM

AMIT ENGINEERS

5.7.1.1 Introduction The Vacuum Evacuation System for Bio-toilet tanks transfer the fecal matter from the bowl/pan to the bio tank by suction and also clean the lavatory bowl/pan with pressurized jet automatically. Two types of vacuum evacuation system with panel:-

Indian Style

Western Style

Indian and Western Style Vacuum Evacuation System

5.7.1.2 Working As the user pushes the flush button, water is splashed and Ejector starts working leading

to creating a negative pressure (vacuum) in the intermediate tank

As soon as the vacuum is created the excreta is sucked from the bowl to the intermediate tank.

Now Ejector starts working again to creating a positive pressure in the intermediate tank.

After that the outlet valve is opened and the waste is pushed to the Bio digester tank



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Pneumatic Scheme



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Controller is designed to work on 110V DC supply and no further requirement of DC-DC converter (110V-24V DC supply)

Western/Oriental bowls is equipped with level sensor to avoid flooding due to any circumstances of blockage in the system.

The amount of water consumption needed for effective cleaning of the Western/Oriental bowl is about 0.5 to 0.7 liters.

The air is supplied at 6 bar, System is able to work at 4 to 6 bar.

5.7.1.3 Components Push Button

Indicator

Vacuum Evacuation System Working

Vacuum Evacuation System Fault



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Vacuum Controller Cabinet

Controller

Port Valve

Sol. Valve Assembly

FR Assembly

Pressure Switch



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5.7.1.4 Interface Requirements Piping requirements Water : Pipe 16x2mm with steel clamp Air : Pipe 8x1mm Drain : DN 40

Air Connection Setting pressure : 4.6 bar Working range : 4 to 6 bar

Water Connection 0.05 to 1.5 bar

Electricity supply 110 VDC

OASIS FABRICATION

5.7.1.5 Introduction The Vacuum Toilet System provides robust design, reliable, safe, simple to operate and passenger friendly and require minimum maintenance. The use of vacuum toilets provides a similar level of comfort as traditional flush toilets, but they use much less water due to the high vacuum suction of the toilet waste after flushing. This results in a minimal requirement of water (0.3 liters) for the transport of faecal and urine. 5.7.1.6 Specification Ambient Conditions: Altitude: Sea level to 2500m Operating temperature: 1 Deg C to 55 Deg C Max. Temperature under Sun: 70° C Relative humidity: up to 95%

Consumption: Water consumption per cycle: 0.4 to 0.5 liters Power consumption per toilet: 9.12 W Solenoid Valve: 5 X 1 = 5 W Digital Pressure Switch: 0.72W PLC: 1.5W MCB: 0.5 W Power Supply: 0.4W Wiring, push button: 1W HMI: 5W

Supply Power Supply: 24V DC Water Pressure: > 0.05 bar Working Pressure: 5 to 6 bar



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5.7.1.7 Components

Lavatory pan/ bowl (Indian squatting/ Western design)

Western & Indian Squatting Toilet

Inlet Valve

Inlet Valve

The system further comprises a flushing valve or an inlet valve. The inlet valve is acting as the interface between the lavatory pan and the intermediate tank. Furthermore, the flushing valve is designed as a rotary ball valve/Pinch valve. The valve is adapted to regulate and control the flow of waste from the toilet bowl to intermediate tank. Moreover, the flushing valve is actuated automatically by a microprocessor unit pneumatically.

Outlet Valve The outlet valve is acting as the interface between the intermediate tank and the bio-digester tank. The flushing valve is designed as a rotary ball valve/ Pinch valve. The valve is adapted to regulate and control through pneumatically.

Intermediate Tank / Vacuum Tank Intermediate tank can be described as vacuum toilet tank is preferably such a desired application. In such an intermediate tank in order to empty the lavatory pan, so that negative pressure is generated, such that the delivery exhaust. This tank is to hold the



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waste during the flush cycle. The intermediate tank can handle -80KPa of working pressure.

Intermediate/Vacuum Tank

Vacuum Ejector It generates the vacuum by a flow of compressed air. It also exhausts the unwanted gases from the system.

Air Filter Regulator An air line filter cleans compressed air. It strains the air and traps solid particles (dust, dirt, rust) and separates liquids (water, oil) entrained in the compressed air. Also maintains a constant output pressure regardless of variations in the input pressure.

Air Filter Regulator

Water Booster Amplifies the water pressure to generate enough flow through the flush nozzles to clean the toilet bowl



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Water Booster

Electrical Panel



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Comprises of microprocessor, Switched mode power supply (SMPS), Miniature Circuit Breaker (MCB), pneumatic solenoid valves, pneumatic piping and electrical wiring.

Control Circuit:



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Double Pole MCB: Effective touch protection when grasping and manually operating the latching slide with latch-down option. Easy to mount on busbar assembly. The 5SL MCB are suitable for the quick and easy mounting of arc fault detection devices, auxiliary switches, fault signal contacts, shunt trips and under voltage releases.

PLC

Digital Pressure Switch: A high function type has analog voltage output operation indicator lights. Current value is shown as main display and set value is the sub display section of the main display.

Digital Pressure Switch

5.7.2 WATER LEVEL INDICATOR AMIT ENGINEERS

5.7.2.1 Introduction Water level indicator is used to indicate the level of water in the tank at convenient place from where the level of water in tank can be seen in trains during journey. It helps railway staff in taking decision to fill up the tank at coach watering station. Previously the mechanical gauge is used but it is not visible during night journeys.



Page 13 of 31

5.7.2.2 Components Electronic Water Level Indicator has 10 LEDs in each level which shows the level of water inside the tanks. The Three levels are:

FULL - Green LEDs ON

HALF - White LEDs ON

LOW - Red LEDs ON

Water Level Indicator consists of three major components:-

Primary Display Unit / Controller Unit.

Two secondary display units.

One Sensor Units.

Water Level Indicator

5.7.2.3 Operation Sensor unit contain hermetically-sealed reed switches in the stem and a permanent magnet in the floats. As the float rises or falls with the level of the liquid, the reed switch is activated by the magnet in the float.

Sensor Unit Construction

A reed switch is an electromagnetic switch used to control the flow of electricity in a circuit. They are made from two or more ferrous reeds encased within a small glass tube-

Secondary Display Unit

Primary Display Unit

Sensor Unit



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like envelope, which become magnetized and move together or separate when a magnetic field is moved towards the switch.

Magnetic Reed Switch

5.7.2.4 Installation Primary Display Unit indication water level is installed inside the coach near toilet area. Two secondary display units are installed outside the coach at the top of the toilet window on either side of the coach. Sensor Unit installed in the tank.

Primary Display/Controller Unit Installation Position

Secondary Display Unit Installation Position ( Either side of the coach)



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There are three connection points mounted on the Primary Display / Controller Unit:-

110 V DC/AC

Output connections for Secondary Display Units.

Input Sensor Connections

Connections – Primary Display Unit

Wiring Details 110 V AC/DC 110 V DC/AC ---------- Black & Red Wire

Secondary Display Units Low ------------ Red Wire Medium ------- Yellow Wire High ----------- Blue Wire Common ------ Grey Wire

110 V AC/DC

Output connections for

Secondary Display Units

Input Sensor Connections

110 V AC/DC Connection

Secondary Display Unit Connection



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Input Sensor Wiring Connections Low ------------ Red Wire Medium ------- Yellow Wire High ----------- Blue Wire Common ------ Black Wire

Secondary Display Units Connector View

Input Sensor Connection

Secondary Display Units



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5.7.3 CHILD PROTECTION SEAT EURONICS

5.7.3.1 Introduction Child protection seat allows parents to comfortably secure a child while using toilets. Warning:

Do not stay away from child, Never leave child unattended.

Take care of the child, Avoid serious injury from falling or sliding out.

Always use restraint belt when using.

Children forbidden hanging on the unit, there are risk of falling.

Designed for children only, Age up to 5 years and weighing less than 25kgs

5.7.3.2 Parts and hardware

Parts of Child Protection Seat

1. Mounting holes 2. Seat back 3. Restraint belt 4. Restraint belt length setting 5. Screws

5.7.3.3 Installation Drill holes at approximately 500 mm above ground level with 440 mm vertical distance

and 180 mm horizontal distance.

Holes should be of 10 mm dia. and 80 mm depth.

Mount the seat with the help of screws.

Refer picture for details



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Position of holes in Child Protection Seat

5.7.3.4 Method of Usage Unfold the unit.

Put the child on the seat, fasten the seat belt and adjust safety belt length.

After use, close the table.

5.7.4 PASSENGER INFORMATION SYSTEM ARECA

5.7.4.1 Introduction The system is designed as a standalone unit and capable of being integrated with a centralized system like RTTIS. It will be operate on 110 V AC or 110 V DC input for its operation. Position Data of the current station location is received from GPS Satellites through GPS receiver module attached with antenna. The location data received from the GPS unit is processed by the Coach Processor Unit and message of passenger interest will be generated. The CPU provides an RS485 Port for transmission of the compiled messages to various kinds of display devices like Slave LED display, Slave LCD displays (for first class coupes) and to Audio Announcement Unit.

Wherever required, the CPU will also be integrated with a Digital Signal Processor (DSP) based Audio Announcement Unit for generating voice messages.

5.7.4.2 Components GPS receiver affixed in the CPU with antenna mounted on coach roof with protective

cover.

Coach Processor Unit with requisite embedded software and having

GPS receiver

RS485 port for communicating with the slave LED and LCD display devices and outside destination boards.

RS485 port for communicating with the centralized RTTIS system.

1 2



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USB 2.0 compliant port for data transfer device.

Audio Announcement Unit, if required.

Power Supply Unit along with DC-DC converter.

LED display modules and Driver circuitry for LED panels.

Menu-operation Alphanumeric Keypad for configuring the system in a standalone manner.

Slave LED display Panel.

Slave LCD display Points, wherever required.

Provided provision for GPRS Module to interface with antenna.

Provided Provision for VHF Module to interface with antenna.

Auto Brightness sensor for auto dimming of LED displays

IR Sensor for wireless operations through remote

Noise sensor for auto volume adjustments

Serial COM port to interface the PC to see the serial data (programmer purpose).

Block Diagram of the System

System Sub-Modules The system consists of 3 sub modules and one optional module.

Master Display Unit

Slave LED Display Unit

Slave LCD Display Unit

Audio Announcement Unit (Optional/ if required).

5.7.4.3 Installation



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Coach internal wiring diagram for installation

Installation location



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Wiring of PIS RJB – Junction to PIS System

Connectivity from JB to unit

Mounting location of PIS AC –Master Unit



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Master Unit Mounting:

Remove the decolam sheet (10mm thick) near water tank and above the Roof Junction Box.

Make dia 10mm holes PIS System mounting holes as per drawing

Fix the Master unit on the decolam sheet.

Fix the Power, Communication & Audio Junction boxes near the Roof Junction Box.

Route & connect the power and communications cables as per wiring diagram.

Fix the decolam sheets (with PIS unit).

Connect the cables to junction boxes.

Slave unit mounting

Remove the decolam sheet (10mm thick) near water tank and above the Wash basin.

Make dia 10mm holes PIS System mounting holes as per drawing.

Fix the Slave unit on the decolam sheet.

Fix the Power, Communication & Audio Junction boxes near the Roof Junction Box.

Route & connect the power and communications cables as per wiring diagram.

Fix the decolam sheets (with PIS unit).

Connect the cables to junction boxes.

Speaker Mounting:

Make the 17”x 15” cutout on the In side Roof.

Fix the speaker on 19” x 17” decolam sheet and mount the same to Roof. (Speaker I&II).

GPS Antenna Mounting:

Weld the GPS Antenna mounting base on the coach roof top.(Near Roof Junction Box Side)

Ensure the welding should be leak proof.

Make dia 16mm hole on the roof top through Antenna Mtg. Base

Insert the cable grommet.

Mount the GPS Antenna assy on the base and take the antenna cable through Grommet.

Connect the Antenna SMA connector to Master unit.

5.7.5 INFOTAINMENT SYSTEM FUNTORO

5.7.5.1 System Overview Network topology



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Network topology Diagram



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Power Connection

Power Connection Schematic

Monitor Assembly

10” Monitor Assembly



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Components of 10” Monitor Assembly

System Built Up

System built up components

5.7.5.2 Monitor Installation Seat preparation

Steps of seat preparation

STEP 1: Set up monitor cable.



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Protect cable by corrugated tube.

Make sure the tube is tied.

Reserved the POE cable length 20cm at least for plugging connector to monitor, and 8cm for Aux-in / Audio Out cable.

STEP 2: Install bracket that to hold monitor’s holder and hinge. STEP 3: Install set rear cover. Use corrugated tubing fitting to protect cable

Use S8 Second Lock to protect cable



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To install monitor on the seat The material of hinge and holder.

Screw set 1: To fit holder-hinge-monitor bracket. Screw set 2: To fit holder-hinge-monitor bracket. Screw set 3: To fit holder-hinge. Screw set 4: To fit monitor to hinge.

Holder and hinge assembly



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Screw set 1: There are 6 screws (M5 x 10mm) to fit Holder-Hinge-Seat Bracket. Screw set 2: There are 2 screws (M5 x 10mm) to prevent holder frame variant by sponge bounce. Screw set 3: These 2 screws to fit Holder-Hinge. Screw set 4: To fit monitor. The steps to install monitor on the seat. Step 1: To fit hinge on the seat bracket by 3 (M5 x 10mm) screws

Step 2: Monitor cabling 1. Plug POE cable to monitor. 2. Put the cable into groove. 3. Stick tape to fit cable in groove

Step 3: Connect AUX-IN and SPK-OUT cable for protect connector. Choice A: Use “S8 Second lock”



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Choice B: Please tape the joint to firm the connection, and settle down and hide the cables between hinge and seat sponge.

Step 4: Fit monitor on hinge. 1. Hook the monitor into T-slot of hinge.

Pull up hinge.

Monitor hook into hinge’s T-slot.

Monitor pull down, make monitor hook is locked.

Make sure the hook is on position.

2. To fit monitor by screw set 4 (M2 x 6mm) screws.



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Step 5: Holder Assembly. Pull up monitor to 45° ~ 60° degree. Assemble the holder to hinge through the hole of holder.

Step 6: Fit holder to hinge and seat bracket by screws, there are 5 screws (M5 x 10 mm) need to be applied (Screw set 1 and 2).

Monitor connection



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5.7.5.3 G Mouse Installation

5.7.5.4 3G Router Installation Use “Giga to RJ45 Cable” link server Giga Port 2 with 3G router.

LHB Technological Development 5. Maintenance -Vistadome

IRCAMTECH/GWL/MECH/2021-22/LHB/HB/1.0 P a g e 1 of 38

5.8. VISTADOME



Contents 1 Operation, Service & Maintenance of Vista-dome Coach .............................................................. 5

1.1 AUTOMATIC SLIDING DOOR: (QTY: 2nos per Coach) .............................................................. 5

1.1.1 SCHEMATIC DRAWING: ................................................................................................... 5

1.1.2 OPERATION: .................................................................................................................... 6

1.1.3 INSTALLATION PROCEDURE: ........................................................................................... 7

1.1.4 UNMOUNTING ARRANGEMENT: .................................................................................. 10

1.1.5 TOOLS AND EQUIPMENT FOR MOUNTING: .................................................................. 10

1.1.6 TROUBLE SHOOTING ..................................................................................................... 10

1.2 180 DEG. ROTATABLE RECLINING PASSENGER SEATS: (QTY: 22 Sets per Coach)................. 12

1.2.1 DESCRIPTION: ................................................................................................................ 12

1.2.2 SEAT MOUNTING PROCEDURE: .................................................................................... 14

1.2.3 SEAT REMOVING PROCEDURE: ..................................................................................... 14

1.2.4 SEAT SPARE: .................................................................................................................. 14

1.2.5 SEAT MONTHLY MAINTENANCE: .................................................................................. 14

1.2.6 SEAT TROUBLESHOOTING: ............................................................................................ 14

1.3 ELECTRICALLY CONTROLLED ROOF OPALASCENCE GLASS UNIT: (QTY: 5 LH + 5 RH per Coach)

15

1.3.1 DESCRIPTION: ................................................................................................................ 15

1.3.2 TECHNICAL SPECIFICATION: .......................................................................................... 15

1.3.3 USAGE OF PRIVA LITE: ................................................................................................... 15

1.3.4 MAINTENANCE OF PRIVA LITE: ..................................................................................... 16

1.3.5 MOUNTING ARRANGEMENT: ........................................................................................ 16

1.3.6 UNMOUNTING ARRANGEMENT: .................................................................................. 16

1.3.7 TROUBLESHOOTING ...................................................................................................... 17

1.4 TOILET (EURO TYPE): ............................................................................................................. 17

1.4.1 DESCRIPTION: ................................................................................................................ 17

1.5 Water System: ....................................................................................................................... 18

1.5.1 DESCRIPTION: ................................................................................................................ 18

1.5.2 SCHEMATIC LAYOUT OF WATER FLOW SYSTEM: .......................................................... 18

1.5.3 MOUNTING ARRANGEMENT:........................................................................................ 18

1.5.4 MAINTENANCE DETAILS: ............................................................................................... 18



1.5.5 Troubleshooting Details: ............................................................................................... 19

1.5.6 SPARES: ......................................................................................................................... 19

1.5.7 SPECIAL TOOLS AND EQUIPMENT: ................................................................................ 19

1.6 PUBLIC ADDRESS-CUM PASSENGER INFORMATION SYSTEM BASED ON GPS,

ENTERTAINMENT SYSTEM: ................................................................................................................ 20

1.6.1 SCHEMATIC DIAGRAM: ................................................................................................. 20

1.6.2 MOUNTING ARRANGEMENT ......................................................................................... 20

1.6.3 UNMOUNTING ARRANGEMENT.................................................................................... 20

1.6.4 TOOLS REQUIRED: ......................................................................................................... 21

1.6.5 GENERAL SETTINGS & OPERATION FOR PAPIS & ENTERTAINMENT SYSTEM CONTROL

UNIT: 21

1.6.6 TROUBLE SHOOTING: .................................................................................................... 22

1.7 PASSENGER CABIN LIGHT: ..................................................................................................... 23


1.7.2 MOUNTING ARRANGEMENT:........................................................................................ 23

1.7.3 DISMOUNTING ARRANGEMENT: .................................................................................. 24

1.7.4 TOOLS REQUIRED: ......................................................................................................... 24

1.8 LAVATORY & GANGWAY LIGHT: ............................................................................................ 24




1.8.4 SPARES: ......................................................................................................................... 25

1.8.5 TOOLS REQUIRED: ......................................................................................................... 25

1.9 OBSERVATION LOUNGE: ....................................................................................................... 25




1.9.4 TOOLS REQUIRED: ......................................................................................................... 27

1.10 MINI PANTRY CAR ................................................................................................................. 27

1.10.1 HOTCASE ....................................................................................................................... 27

1.10.2 MICROWAVE OVEN: ...................................................................................................... 28

1.10.3 COFFEE MAKER: ............................................................................................................ 30

REFRIGERATOR: ............................................................................................................................. 30

1.10.4 BOTTLE COOLER: ........................................................................................................... 31



1.11 AIR CONDITIONING: .............................................................................................................. 32

1.12 ASPIRATION BASED AUTOMATIC SMOKE AND FIRE DETECTION SYSTEM (RDSO/SPEC/CG-04)

35

1.13 Operating Principle ............................................................................................................... 35

1.13.1 Main Components ......................................................................................................... 37

1.13.2 Inspections .................................................................................................................... 37

1.13.3 Maintenance ................................................................................................................. 37

LHB Technological Developments 5. Maintenance -Vistadome


1 Operation, Service & Maintenance of Vista-dome Coach

1.1 AUTOMATIC SLIDING DOOR: (QTY: 2nos per Coach)

The Automatic Sliding door is fitted on one end of the passenger area and between the

lavatory and Luggage Rack area on the other end, thus separating the Air Conditioned

Passenger Cabin from rest of the coach. The door provides easy access for passengers into

the cabin as it senses their movement and opens / closes accordingly. It has a large clear

glass fitted inside a frame. The motor and drive mechanism open / closes the door based on

input from sensor. It is also equipped with a control unit for varying the door characteristics.

An emergency push button is provided on either side of each door, to open the door in case

of any emergency.

The manufacture and working of this door is strictly in compliance with ICF/MD/SPEC 338

Rev: 0 specifications.

1.1.1 SCHEMATIC DRAWING:

Figure 1



1.1.2 OPERATION:

Press the open button to open the door as shown

The door waits for 5 seconds before attempting to close again. In case of emergency, press the emergency button as shown in

The power supply to the door will be cut and the door can be opened manually by hand.

The door is equipped with various sensors to sense any obstacle while the door is closing.

The door opens immediately if any obstacles are present in the pathway.

The door waits for 5 seconds and attempt to close again.

If there is no obstacle, then the door closes normally. If the obstacle is still present even after 3 closing attempts, the door

opens and waits for 30 seconds before it attempts to close again.

The cycle continues as above.

Figure 2 Figure 3

Figure 4



1.1.3 INSTALLATION PROCEDURE:

Figure 5: Mounting Move Mechanism

Fix the move mechanism with M8 Screws (X10) and M8 Nylock nut to coach body at 1960 mm from floor

Use Spacer as per requirement to centre the door to the pocket.

Fix the bottom guides, smaller one on the & bigger one on the pocket side as shown.

Fix the body side rubber using self screw.



Figure 6: Fixing Body Side Rubber

Fix the door using M10 Screw provided at the top of door and connect wire from move mechanism to the door

Figure 7: Fixing Door



Fix the control panel and make the interconnections from move mechanism and control panel

Figure 8 : Fixing Control Panel

Provide the power to the system through emergency switch provided, one inside and one outside

Figure 9 : Supply of power through emergency switches



1.1.4 UNMOUNTING ARRANGEMENT:

Disconnect the power supply going into the control panel.

Remove the wiring connection between door & move mechanism.

Remove the wiring connection move mechanism & control panel including motor.

Unscrew control panel and remove the same.

Loosen the 3x M10 bolt provided at the top of the door and remove the door from move mechanism.

Unscrew the bolts holding move mechanism and remove the same.

Store the Item in safe condition.

1.1.5 TOOLS AND EQUIPMENT FOR MOUNTING:

1. Drill Machine 2. Rivet Gun

3. Spirit level 4. Torque Wrench

5. Extension cable 6. Spanners Screw Drivers

1.1.6 TROUBLE SHOOTING

S.No. Problem Possible Cause Solution

1 Door does not open/close Emergency Switch is activated

Release the emergency switch

Power supply is not present/adequate

Check the power input if it is within 90-125V

SMPS not switching ON Check for any short circuit within the system

Check if SMPS is working or else replace it.

2 Door does not close after opening

Proximity sensor failed Adjust the proximity at the open end

Replace the proximity if failed

Check if signal from the proximity at the open end goes into the logic controller

Logic Controller/ Monitor failed

Check the power supply & connection going into the same

Replace the same if failed

3 Door does not open /door stops halfway through opening stroke

Failure of proximity sensor at close end

Adjust proximity at closed end to activate when door is present at the spot

Replace the proximity sensor if failed

Check if signal at the



proximity at close end goes into the logic controller

4 Door does not move Door is stuck Check for any obstacle around the door/move mechanism

Lubricate the Guide Rod

Motor is jammed Check for the connection of motor

5

Door does not slow down

Failure of proximity sensor at the middle (near open /close)

Adjust the proximity at the middle to activate when door is present at the spot.

Replace the proximity sensor if failed

Check if signal at the proximity goes into the logic controller

6 Door hits the open end while opening

Combination of problem no. 2 & 6

Check for the solution as per problem no 2 & 6

7 Door hits the open end while closing

Combination of problem no. 3 & 6

Check for the solution as per problem no 3 & 6

8 Door switch does not open the door

Failure of door switch Check if the signal from switch goes into the logic controller


9 Door sensor does not work

Edge sensor failed Check if the signal from edge sensor goes into the logic controller


Motor sensor failed Check for the interconnections from logic controller & motor drive.

Table 1



1.2 180 DEG. ROTATABLE RECLINING PASSENGER SEATS: (QTY: 22 Sets

per Coach)

1.2.1 DESCRIPTION:

Another unique feature in this coach is the 180 degree Rotatable Double seater offers a panoramic view of the surroundings to the passengers. Like in other elite coaches, these seats also have reclining operation, charging socket under each seat, Snack tables can be unfolded from arm rest, Bottle and Magazine holder in the back rest of each front seat. Additionally each pair of seats is mounted to the floor by a single shaft mechanism that allows the seat to be rotated on any direction as per the passengers wish. A Push button beneath the Arm rest will allows the back rest to be reclined. A 3 step adjustable foot rest for each seat is given below the front seat of each seat.

S.NO PART NAME REMARKS

1. Fasteners Stainless Steel

2. Side Cover and Arm Rest Base Cover

4mm thick FRP part painted with RAL: 9006 colour

3. Trim for Seat Fabric as per MDTS – 219 rev-2, as per approved sample

4. Seat base foam support 19mm BWR plywood used & covered with fire barrier cloth

5. Back Covering PVC vinyl fabric (Rexine) with stitched mag pouch as per customer approved sample

6. Front Rest Assy. 3 position adjustable al. Foot rest Assy.

7. Seat and Backrest Cushion PU foam-spec RDSO/2007 cg-04 with toxicity <2.5 tested. As per NCD - 1409 & fully covered with fire barrier cloth. To meet en-45545-2 hl3 r-21 requirement

8. Snack Tray Foldable snake tray (sunk in type in middle arm rest). (PDC AL: ADC 12) & powder coated RAL 9006.

9. Seat Frame Assy. Seat & back rest frame ss-304

10. Seat Back Rest Assy. Foam in place with SS fabricated frame structure

11. Seat base and Back rest Frame, MTG Base

Fabricated SS304 structure and Silver Grey RAL:9006 Powder coated.

Table 2



Figure 10 : 180 DEG. ROTATABLE RECLINING PASSENGER SEATS

Figure 11: 180 DEG. ROTATABLE RECLINING PASSENGER SEATS

Salient Features: 1. Wider 2X2 seating with 180 Deg Rotation 2. Ergonomically designed seat contours 3. Foldable Food Tray with arm pad console 4. Molded PU foams covered with EN -45554 fire barrier cloths. 5. Backrest foam integrated with Neck support 6. Backrest Reclining through Gas Springs 7. ISF foam pad armrest assemblies 8. Stainless steel structural parts



9. Magazine pouch at backside of back rest 10. Bottle holder at backside of back rest 11. Laptop Charger points in Seat 12. Grab handles in Seat Backrest Side

1.2.2 SEAT MOUNTING PROCEDURE:

1. Place the drilling jig at seat support profile in side wall and marking/drilling/tapping the holes in floor for fixing of seats as per respective drawing. Removing the chip from holes carefully.

2. Load the seat in the coach carefully, set the location and fix the screws (already provide in seat attachment profile) and floor with help of adequate as per respective drawing

1.2.3 SEAT REMOVING PROCEDURE:

Clean the workplace and Remove the fasteners using proper tools, then safely taken

out seat from flooring.

1.2.4 SEAT SPARE:

1 Side arm rest 2 Middle arm rest pad 3 Snack table 4 Bottle holder 5 Rotating lever 6 3 step foot rest

1.2.5 SEAT MONTHLY MAINTENANCE:

a. Clean the Seat cover, mounting arrangement and connecting parts. b. Inspect rotating arrangement of seat mechanism. c. Change outer seat cover periodically.

1.2.6 SEAT TROUBLESHOOTING:

PROBLEM COMMON CAUSES SOLUTION

Seat flops back not in use Loose tension spring and broken mechanism

Replace and install mechanism.

Seat jerks forward while seated Commonly a worn away the pivot pin metal mechanism

Replace mechanism

Nothing happens while activating lever

In proper usage of lever Replace of lever and its continuity parts

Table 3



1.3 ELECTRICALLY CONTROLLED ROOF OPALASCENCE GLASS UNIT: (QTY: 5

LH + 5 RH per Coach)

1.3.1 DESCRIPTION:

The most important feature of this Vistadome Coach is this Opalescence Roof Glass. The name Tourist car makes sense when this roof window gives passengers a view beyond its limit. The opening in roof allows viewing area from ground to the sky. The Opalescence feature plays a vital role in controlling the incoming sun light by electrically controlling its transparent feature to opaque. Totally 10 (5 LH and 5 RH) opalescence glass units are provided in the roof and they are controlled by a single control box unit fitted inside the Service station.

1.3.2 TECHNICAL SPECIFICATION:

PRODUCT DESCRIPTION: 33mm Thick Double Glazed Laminated Glass, 6mm SGG Planitherm Tempered + 16mm Air gap with Argon Gas + 12mm Priva Lite Glass (Switchable Glass) Tempered laminated Glass. PLANITHERM: High Performance Solar Control Glass with Advanced Thermal Insulation Properties, it has high performance coatings, the coating is applied on the SGG Planiclear float glass by Cathodic magnetron sputtering under vacuum condition. BENEFITS:

1. It has a high light transmission. 2. Very low g value which reduces the solar gain by as much as 50% compared

to standard thermally insulated glass. 3. It has an excellent U value of 1.0W/m2K. 4. It has High degree of neutrality both transmission and exterior reflection.

PRIVA LITE GLASS (SWITCHABLE GLASS): PRODUCTS & ITS FUNCTIONS:

1. It is a tempered laminated safety glass (According to EN 14449) using EVA foil.

2. It is composed 2 extra clear glasses which encapsulates a liquid crystal film inserted between EVA layers.

3. Due to voltage application liquid orient them towards the same direction, and glass switches from translucent to transparent with almost no alteration of light transmission.

4. When Power off condition It will be translucent stage, and become transparent when 230 voltages is applied.

1.3.3 USAGE OF PRIVA LITE:

The use of PRIVA-LITE strongly depends on the control system and the electrical installation. It starts from the on/off wall switch provided by your electrician up to control systems that can help you to run the PRIVA-LITE automatically. To keep the good working of the PRIVA-LITE over time, it’s recommended to check annually that



All wiring is in good condition. Framing materials are free of any damage. Transformer and switch are in good visible order. Walls, ceilings and floors are not humid.

The PRIVA-LITE CLASSIC is consuming up to 7W/m² in transparent mode (ON) while PRIVA-LITE XL up to 5W/m². It’s by consequence strongly recommended for environmental reasons, but also to keep. The good working of the PRIVA-LITE and to avoid hiding power reduction in diffusing mode (OFF) over time, to not leave the PRIVA-LITE panels continuously in transparent mode (ON). It’s recommended to have PRIVA-LITE in OFF position for at least 4h per day continuously. Avoid hot spots such as light spot, cooking table top close to PRIVA-LITE. Temperatures over 60°C damage the PRIVA-LITE.

1.3.4 MAINTENANCE OF PRIVA LITE:

Clean the PRIVA-LITE like any other glazing. Make sure that PRIVA-LITE panel is OFF when cleaning it. Regular cleaning with neutral materials is recommended for optimum

performance. REQUIRED CLEANING TOOLS: A soft, clean lint-free cloth /chamois leather/ a clean soft non-abrasive sponge/a clean, non-metal window squeegee. Do not use steam cleaners (Polti) or pressure cleaner (Kärcher) as this would generate water infiltrations and short circuits, and bring temperatures over 60°C. All cleaning tools must be kept clean. This is to prevent any dirt or abrasive particles transferring from the equipment back onto the glass which may scratch or damage the glass.

1.3.5 MOUNTING ARRANGEMENT:

1. Remove the glass carefully from its packing & place it on the flange above the strips & Make sure glass fits perfectly inside the frame.

2. On the outer side of Roof, do the necessary masking work around the window cut out.

3. Apply sealant on the outer side of Roof around where glass touches the roof sheet.

4. Remove the excess sealant by removing the masking tape. 5. Clean them by mild soap oil & keep the window setup undisturbed for the

sealant & adhesive to cure.

1.3.6 UNMOUNTING ARRANGEMENT:

1. Tare the inner and outer sealant then safely remove the roof top opalescence glass from shell window cut -out.

2. Remove the cables connected with the roof glass.



1.3.7 TROUBLESHOOTING

Table 4

1.4 TOILET (EURO TYPE):

1.4.1 DESCRIPTION:

The Euro type FRP Modular toilet is constructed and assembled as a single part and then fitted entirely as a unit inside the coach. Euro 1 Exterior consist of Dustbin with Rack for Fire Extinguisher and Euro 2 Exterior will have Wash Basin, Soap Tray and Mirror. The walls, ceiling, sink table are made of FRP, while the sink & western style commode are made of stainless steel. Latches, Hinges, taps, Hoses, Handle, Faucet, occupancy indicator & Locks are bought from commercially available reputed brands and models. The outer side of this unit has a FRP dust bin with a lid & below is the space for keeping Fire Extinguisher. The ceiling of this lavatory is having openable arrangement, to do any maintenance or repair works on the Auxiliary water tank, fitted above the lavatory. Pressurized Flushing System in the lavatory is provided with pressure- assisted toilet flush system which combines the gravity flushing system with compressed air.This system is used to create a powerful flush in toilets where gravity flush system on its own would not be sufficient like in rear-discharge and upflush toilets. S. NO ITEM BRAND / MAKE

1. Self-Closing Gravity Cock Parry ware / Jaguar

2. Health Faucet Parry ware / Jaguar

3. Press matic self-closing Bib Cock Parry ware / Jaguar

Figure 12

POSSIBLE CAUSE REMEDY

A Component (cable, connector, control unit) are broken or damaged.

To follow maintenance procedure and solve properly.

Check wiring and sensor circuit

Nothing appears in the display screen when control unit is turned on

Charge the control unit battery .if problem check the wiring circuit

Broken glass Check roof top glass around sealant area.



Figure 13

1.5 Water System:

1.5.1 DESCRIPTION:

Auxiliary Water Tank of capacity 30 litres -2 no. each located on the Lavatory end roof provides water for the toilet system. The water is received from the under slung water tank of capacity 685 litres – 2nos. The water is pumped into Auxiliary tank with 1HP Double pump. The water intake on the Auxiliary water tank is flown through the S.S Pipelines routed in the coach.

1.5.2 SCHEMATIC LAYOUT OF WATER FLOW SYSTEM:

See at Annexure I


1. Cutaways (if required) for the Lavatory and Piping shall be made on the under-frame.

2. The assembled FRP Modular Toilet shall be erected from the top roof through RMPU opening of the coach.

3. The flanges of FRP Modular toilet shall be screwed into the Sidewall and End wall of the coach.

4. Necessary Pipe Connections and wiring are to be given.

1.5.4 MAINTENANCE DETAILS:

1. Piping/Taps fittings shall be checked and tighten properly to arrest the water leakages.



2. Functionality of all controls i.e., +Flushing lever and water taps. 3. External washing of the tank should be done by pressurized water hydrants. 4. If there is any damage or leakage in the tanks or non-confirming results of

effluent discharges are being reported etc., these tanks should be drained out at designated place having proper drainage, cleaned properly and tank should be rectified for the deficiency noticed.

5. Nut, bolts and spring washers used for mounting bracket and securing of safety rope should be checked for wear, tear or corrosion etc. and should be replaced with same size material and grades if defective.

1.5.5 Troubleshooting Details:

S. No. Problem in Maintenance Steps to be taken

1 Choking of Toilets:

Due to accumulation of Garbage in toilet pan thrown by passengers i.e. plastic bottles, newspapers, sanitary pads and tea cup etc.

Display Laminated Stickers in the toilets for sensitizing the Passengers “Not to throw foreign materials” in toilet.

Provide Dust Bins

Garbage Picking Tongs should be used to avoid manual scavenging and also for easy removal of garbage from toilet pans.

Choke Remover Devices should be kept in Coaching depots & enroute stations to clear P- Trap jam

2. Foul smell:

Due to leakage of effluent from Rubber Hose Connector or Colonized Rubber gasket.

a) Check the leakage from Rubber Hose Connector due to uncoupling from toilet pan due to loose SS- Clamp of connector in bottom or rupturing on the body. Replace if required.

b) Check the leakage from colonized rubber gasket due to breakage/rupturing. Attend or replace gasket if required.

Table 5

1.5.6 SPARES:

1. Mirror 2. Flushing Lever 3. Taps and Fittings 4. Door Handle 5. Latches

1.5.7 SPECIAL TOOLS AND EQUIPMENT:

1. Pipe Wrench 2. Spanners 3. Screw Driver



1.6 PUBLIC ADDRESS-CUM PASSENGER INFORMATION SYSTEM BASED ON

GPS, ENTERTAINMENT SYSTEM:

1.6.1 SCHEMATIC DIAGRAM:

See at Annexure I

PAPIS CONTROL UNIT: WIFI Router gives wireless internet facility to the passengers. GPS Unit gives information like exact location and speed of the train, distance from next station, destination of the train etc. Digital Destination Board is a digital electronic device that is fitted to the exterior of the coach, displaying the train number, name and its destination. Other parts include USB (Universal Serial Bus), MCD (MillliCandela), COD (Content On Demand) & MBU (Master Board Unit).

ENTERTAINMENT SYSTEM:

LCD displays the information from PAPIS Control unit in Video form, with sound output from Speakers. TV is fitted in all 4 partition walls of Passenger cabin, while speakers are located in the duct panel. PAPIS – (Passenger Announcement cum Passenger Infotainment System) It has a common control unit that integrates and controls the function of the above devices.

1.6.2 MOUNTING ARRANGEMENT

(COMMON FOR PAPIS CONTROL BOX, WIFI, GPS UNIT)

Necessary back pieces are given in the shell as per the location of those items given in the above drawing.

PAPIS Control box, WIFI unit & GPS unit are placed exactly in the location & holes for drilling are marked.

Holes are drilled in the marked area & taping is done on those holes.

The respective devices are aligned to the drill holes & bolted to the back piece.

(FOR LCD TV)

Flat back pieces are welded to the shell partition at the location of TV.

TV is placed and positions for L Angle are marked near top and bottom of the TV

case.

Two L Angles are welded in the marked positions.

The TV case is then aligned and screwed to the L back pieces.

(FOR SPEAKERS)

Necessary back pieces are provided in the FRP panel near the speaker cutout.

Speaker is screwed to these back pieces.

1.6.3 UNMOUNTING ARRANGEMENT

(COMMON FOR PAPIS CONTROL BOX, WIFI, GPS UNIT)

The Items shall be held firmly before removing the bolts.

Once the bolts are removed slowly, the devices can be brought down to a table carefully



(FOR LCD TV)

Fasteners to be removed from the back piece.

TV shall be gently pulled from the L angle clamp & brought down.(FOR SPEAKERS)

Screw shall be removed from the speakers and gently the speakers shall be pulled out of the FRP panel.

1.6.4 TOOLS REQUIRED:

Drill Gun

Drill Bit

Tapping Tool Bolt & Nut Screws

1.6.5 GENERAL SETTINGS & OPERATION FOR PAPIS & ENTERTAINMENT

SYSTEM CONTROL UNIT:

RMPU Menu Structure Default Screen On power-up the following is displayed on the LCD: Line-1: “PIS MPU UNIT ” Line-2: “HW V1.0 ,SW 1.0 ” Line-3: “DB V1.0 ” Line-4: “Long Press ‘ENTER’ ” Entering Menu Mode On pressing ‘ENTER’ for approx. 3sec MPU enters the MENU mode and following Screen appears (line 5, 6, 7 will get by pressing up and down key). Line-1: “SELECT MENU MODE” Line-2: “–>User Mode >” Line-3: “Supervisor Mode >” Line-4: “Factory Mode >” Line-5: “PA Settings>” Line-6: “Audio Volume>” Line-7: “MEDIA>” User Mode On entering User Mode Following screens appear. Line-1: “Enter User Password: ” Line-2: “ ” After Entering 1111(user password) using Alpha Pressing ‘ENTER’ key the Line-1: “Enter Route Number” Line-2: “ ” If the route is not available in the database, it shows the following screen: Line-1: “Route Missing!!!” Line-2: “Select Valid Route!” Supervisor Mode Supervisor mode is only for company not for general user. Factory Mode On entering Factory Mode Following screens appear. Line-1: “Enter Factory Mode Password:”



Line-2: “ ” After Entering 9999(Factory Mode password) using Alpha Pressing ‘ENTER/#’key the The whole system will be reset and after few minutes it will automatically restart. PA Settings (A) On entering PA Settings Following screens appear. Line-1: “PA SETTINGS” Line-2: “--> PA Enable” Line-3: “ PA Disable” PA Enable and PA Disable options can be selected through up and down key of keypad PA Enable: on selecting PA Enable option, mic will enable and pre-recorded message Like next station, present station will stop. PA Disable: on selecting PA Disable option, mic will disable and pre-recorded Message like next station, present station will be start. Note: - by default pa settings disable. Audio Volume (A) On entering Audio Volume Audio Volume can be adjusted through up and down key and press enter to save volume level MEDIA Media option is used to play videos. On entering Media Following screens appear. Line-1: “Enter Media Password: ” Line-2: “ ” After Entering 5577 (media password) using Alpha Pressing ‘ENTER’ key then video list will be displayed and then select any video to play.

1.6.6 TROUBLE SHOOTING:

Main Processor Unit

Issue Probable Cause Corrective Action

Main Processor not working

Power Connector wiring issue Check Power Cable and Power Connector connection

Internet TFT Display not working

Issue Probable Cause Corrective Action

Internet TFT Display Power problem

Power Connector wiring issue Check Power Cable & Power Connector connections

Data is not displayed Ethernet connection problem Check Ethernet cable

Video not play on TFT Display

Video MP4 files not present in video streamer pen drive

Copy Mp4 file in video steamer pen drive with name

V1.MP4………………………..V9.MP4

Side Destination TFT Display not working Issue Probable Cause Corrective Action

Side destination display power

problems

Power connector wiring issue Check power cable & power connector connections

Data not displayed RS485 connection problem Check RS485 Cable



Content on Demand System (COD) Issue Probable Cause Corrective Action

COD not working

Power connector wiring issue Check power cable & Power connector connections

RS485 connection problem Check RS485 Cable

Ethernet Connection Issue Check Ethernet connection

Entertainment content not present in server pen drive

Copy content into server pen drive

Table 6

1.7 PASSENGER CABIN LIGHT:

Figure 14


Model No. : 8553-B Name : 4 F.T. Linear Lighting – Passenger Area, Luggage Rack, SBC Corridor. Specification : 110V / AC / 18W Led. Dimensions : 1206 x 132 x 76 mm.


1. Remove the outer plastic cover so that the aluminum frame of the light will be visible.

2. Place the frame below the back piece location as per drawing. 3. Screw the frame to the back piece through the slot holes provided in the frame. 4. After screwing, check for any shaking or improper screwing. 5. Finally fit the plastic outer cover back in the frame.



1.7.3 DISMOUNTING ARRANGEMENT:

1. Remove the outer plastic cover so that the aluminum frame of the light will be visible.

2. Cautiously remove the screws from the frame. 3. Make sure that the light will not fall down after unscrewing by holding it.


1. Drilling Gun 2. Drill Bit 3. Screw Driver 4. Cutter 5. Cable Connector

1.8 LAVATORY & GANGWAY LIGHT:

Figure 15




Model No. : 8601 Name : Diva Square Down Light – Gangway & Lavatory. Specification : 9W Led. Dimensions : 180 x 155 x 70 mm.


Remove the outer plastic cover so that the aluminum frame of the light will be visible.

Place the frame below the back piece location as per drawing.

Screw the frame to the back piece through the slot holes provided in the frame.

After screwing, check for any shaking or improper screwing.

Finally fit the plastic outer cover back in the frame.



Cautiously remove the screws from the frame. Make sure that the light will not fall down after unscrewing by holding it.

1.8.4 SPARES:

LED Strip. Vevo Connector. Choke.


Drilling Gun

Drill Bit

Screw Driver

Cutter

Cable Connector.

1.9 OBSERVATION LOUNGE:

Figure 16: Observation Lounge



Figure 17: Observation Lounge


Model No. : 3403-A Name : 4 F.T. Linear Lighting– Observation Lounge. Specification : 18W Led. Dimensions : 1200 x 65 x 35 mm.



Place the frame below the back piece location as per drawing.

Screw the frame to the back piece through the slot holes provided in the frame.

After screwing, check for any shaking or improper screwing.

Finally fit the plastic outer cover back in the frame.





Cautiously remove the screws from the frame. Make sure that the light will not fall down after unscrewing by holding it.


Drilling Gun Drill Bit Screw Driver

Cutter

Cable Connector.

1.10 MINI PANTRY CAR

Mini Pantry Car consists of following items depicted in picture below –

1.10.1 HOTCASE

(A) TECHNICAL SPECIFICATION: Drawing No. LE72205; Alt: C

Brand Vishal Gas Agencies

Power Rating 230V / AC Single Pole / 400 W

Built Material SS 304.

ICF Specification No. EDTS 139, Rev: E

(B) MOUNTING ARRANGEMENT:

Thoroughly clean the area before placing Hot Case.

Place the Hot case in the pantry floor according to the drawing.

Arrest its movement using L Corner skirting as a support wrap around the bottom of the Hot Case.

The skirting is screwed to the pantry floor.

(C) UNMOUNTING ARRANGEMENT:

Once the L Corner skirting is removed, the Hot Case can be moved freely.

S. NO ITEM DESCRIPTION

1 Hot Case 2 Microwave Oven 3 Coffee Maker 4 Refrigerator 5 Bottle Cooler 6 SS Corner Sink



(D) TROUBLE SHOOTING:


Hot case not switching on despite giving power input.

No power supply in socket.

Ensure power supply to the socket using multimeter.

Check the input power cable of hot case.

Hot case not heating up when switched on.

Faulty / defective heating coil

Check for warranty & contact supplier.

Table 7

(E) MAINTENANCE: Clean all the trays regularly & also the exterior of the hot case. Ensure working of all controls by turning them OFF & ON regularly even

though they are used rarely.

1.10.2 MICROWAVE OVEN:

(A) TECHNICAL SPECIFICATION: Make : IFB Model No. : 25CS4 Power Rating : 230V / 2kW Capacity : 25 Liters (Min). Dimensions : 483 W x 414 D x 281 H mm

Figure 18

Figure 19




Thoroughly clean the area before the placing Microwave oven.

Install the mounting brackets with supporting piece on both sides to prevent shaking while travelling.

(C) UNMOUNTING ARRANGEMENT:

Remove the supporting piece and brackets from both sides with respective tools and safely remove the Microwave oven from serving area.

(D) TROUBLE SHOOTING:


Microwave oven is not heating up

Fault in Input power socket or cable Burned out in Diode and Magnetron

Ensure power supply to the socket & cable using multimeter.

Check warranty & contact the supplier

Microwave oven stops cooking in the middle

Overheat and shutdown in the middle of cooking due to lack of space for ventilation

Place them microwave oven with sufficient amount of space for ventilation

Table 8

(E) MAINTENANCE: 1. KEEP THE INSIDE CLEAN. By regularly wiping out the inside of your microwave,

you cut down on bad smells and keep spots and corrosion from developing. Food

and liquid left in the oven will continue to cook each time it’s used and will absorb

the energy meant to heat up your current meal, making it less efficient. Clean any

spills and splatters right away, and do a full wipe-down with a mild detergent once

a week to once a month, depending on your usage.

2. KEEP THE OUTSIDE CLEAN. Dust, grease, and other residues can build up on the

outside of your microwave, especially on the controls. Old stains are harder to

clean than new messes, so keep your microwave looking brand new by wiping it

down regularly. This includes the areas around the microwave such as the

countertop or cabinet.

3. USE MICROWAVEABLE CONTAINERS. Non-microwaveable plastic containers can

melt and even leave toxic particles in your food. Make sure you use containers

that are specifically labelled as microwave-safe. These are often made of ceramic,

glass, or tougher plastic.

4. COVER YOUR FOOD. Use a microwave-safe plastic cover over your dishes or use

the lids on your microwave-safe food containers. Splashes happen during the

microwaving process as the liquid heats up, and preventing them from hitting the

walls of the microwave makes clean-up easier and protects the paint and metal of

the oven.

5. NEVER PUT METAL IN YOUR MICROWAVE. The microwaves emitted from the

oven bounce off of metallic materials, so metal in the oven will cause the interior



to heat up unevenly and can cause damage. This includes aluminium.

6. MAKE SURE THE DOOR CLOSES PROPERLY. If the door is damaged or the seal is

cracked, food won’t cook evenly and radiation can escape.

7. Clean in a regular basis at 1 time / month or even before when required.

1.10.3 COFFEE MAKER:

(A) OPERATING INSTRUCTION: Make : Morphy Richards Model No. : FRESCO Power Rating : 230V / AC / 800W Capacity : 15 Cups (Min). Dimensions : 22.2 W x 28 D x 35.2 H mm (Approx.)

Figure 20 Figure 21


Place the Coffee maker above the SS tray. Place L brackets in around 2 sides of the Coffee maker. Mark holes to be drilled in the SS tray & screw the brackets to the tray.

(C) UN MOUNTING ARRANGEMENT:

Remove the screws from the L brackets. Move the L brackets to move the coffee maker.

REFRIGERATOR:

(A). TECHNICAL DESCRIPTION : Make : Whirl Pool

Model No. : 215 IMPWCOLL PRM 4S INC Steel

Power Rating : 230V / AC

Capacity : 200 Litres (Glass Trays).

Dimensions : 531 W x 655 D x 1332 H mm (Approx.)

Power : 4 Star

Figure 22



(B). MOUNTING ARRANGEMENT: Fridge shall be kept as per the location showed in the pantry arrangement

drawing. One end of an L Bracket is screwed to the back piece in the sidewall behind the

Refrigerator. Other end is fitted to the Fridge by screwing, thus preventing its movement

during journey. Foot of the Fridge is covered around with SS skirting, which is screwed to the

floor. (C). UN MOUNTING ARRANGEMENT:

Remove the screws connecting the Fridge & back piece. Remove the screws from the skirting in the bottom. Now the fridge is free and can be moved.

(D). TOOLS REQUIRED: Drill Gun Drill bit Rivet SS Clamp

1.10.4 BOTTLE COOLER:

(A). TECHNICAL DESCRIPTION : Make : Voltas

Model No. : 90 L SD Power

Rating : 230V / 400W

Capacity : 90 L min.

Dimensions : 550 W x 565 D x 830 H mm (Approx.) Figure 23

(B). MOUNTING ARRANGEMENT:

Wood packing shall be provided on both the walls near the Bottle Cooler, which prevents it from hitting or vibrating with the walls.

Bottle cooler is moved to its location as given in the layout pantry drawing.

SS Floor molding is riveted around the Bottle Cooler, thus arresting movement in all directions.

(C). UN MOUNTING ARRANGEMENT:

Remove the SS Floor molding to free the bottle cooler from clamping.

(D). MAINTENANCE:

Clean the doors and the surfaces using a damp soft cloth and mild liquid detergent.

Don‘t use abrasive detergents or powders, since these might damage the surfaces. The unit can be washed on the inside using bicarbonate of soda. Remove the bottom cover at the back of the cabinet and clean the compressor

coil with a brush and vacuum cleaner every three months or when it´s dirty.



1.11 AIR CONDITIONING:

(A). DESCRIPTION FOR DUCT:

Drawing No.: 853-4-4-003; Alt: Nil.

The Air Duct made of Aluminum sheet, circulates and conditions the temperature of air inside the coach, thus giving the passengers a comfortable feel throughout their journey at all weather conditions. The duct has 2 major parts: Supply Air Duct and Return Air Duct. As its name implies, the supply air duct brings fresh, conditioned air from outside to the inside of the coach, through a Roof Mounted Power Unit (RMPU). This comes down to the cabin from the main duct through a diffuser box and then out of the Aluminum extruded grill. The supply duct is designed in such that air is supplied to the cabin at a high and constant velocity, without creating any noise. The Return air grill connects passenger cabin to the RMPU, from all the 4 partitions inside the cabin. Air from the cabin is returned back to the outer environment by the RMPU. Temperature sensors are fitted inside the return air grill, to monitor the air temperature & react based on it. Melamine foam insulation covers the entire duct to prevent water dripping by condensation due to exposure to the outside heat.

(B). DESCRIPTION FOR RMPU : The Roof Mounted AC Package Unit of LHB Coaches is a Microcontroller based unit

developed to control the sub-systems of the RMPU automatically according to the

Heating, Ventilation and Air-Conditioning (HVAC) algorithm to provide accurate

control thus resulting in comfort to passengers.

(C). MOUNTING ARRANGEMENT:

AIR DUCT:

All Air ducts shall be fabricated & brought into the coach as each separate sub assemblies (10 Supply Air Ducts, Connector part, Connecting part, Compensation part, Return air Duct) etc.

Each duct is lifted to the roof and arranged in the order of the above given Duct arrangement drawing, after wrapping them around with Melamine insulation.

Return air ducts are fitted in the 4 corners of the coach.

Diffusers are fitted to the bottom of each sub duct.

L angle back pieces are welded below the diffusers on either side longitudinally, along the length of the coach, in passenger area.

Rubber Gasket is stuck to the bottom of the above back piece. Aluminum Diffuser grills are then screwed to the back pieces

RMPU:

After Trough is fitted on the roof, the RMPU is lifted above the FRP trough.

All 4 corners of the RMPU has bolting arrangement.

These are fitted on the brackets provided in the shell on all 4 corners.

Make sure that ventilation area for Condenser Air Inlets and Condenser Air Outlets are not obstructed and condenser fans can rotate freely.

Also ensure that fresh air intake opening are not blocked or covered. 3.4 Ensure that the trap door and opening for the filters are not obstructed and that covers



of these openings can be removed freely. 3.5

Also ensure that filters can be pulled out easily. 3.6 Connect thermostat and control panel to their respective matching terminals in the PAC unit.

Connect numbered power terminals of the PAC unit to respective numbered terminals in the control panel.

Re-check and tighten all screws, terminals, fuses and all control and power connections for their correctness. 3.8 Connect the power supply (415 V AC, 3 phase, 50 Hz) to the power input terminals.

(D). UNMOUNTING ARRANGEMENT:

AIR DUCT:

The FRP panels located in the roof shall be unmounted first.

After unmounting the FRP, the Aluminum Grill & its back pieces shall be removed.

From then, each sub assembled duct shall be brought down after removing the rivets.

Return air duct shall also be removed in the same manner. RMPU:

All the bolts in the 4 corners shall be loosened and removed.

The RMPU should be lifted steadily using lifting equipment and gently brought down.

(E). TOOL REQUIRED :

Lifting Equipment

Spanner

Wrench

10 mm Box

(F). DESCRIPTION FOR DUCT: The Air Duct made of Aluminum sheet, circulates and conditions the temperature of air inside the coach, thus giving the passengers a comfortable feel throughout their journey at all weather conditions. The duct has 2 major parts: Supply Air Duct and Return Air Duct. As its name implies, the supply air duct brings fresh, conditioned air from outside to the inside of the coach, through a Roof Mounted Power Unit (RMPU). This comes down to the cabin from the main duct through a diffuser box and then out of the Aluminum extruded grill. The supply duct is designed in such that air is supplied to the cabin at a high and constant velocity, without creating any noise. The Return air grill connects passenger cabin to the RMPU, from all the 4 partitions inside the cabin. Air from the cabin is returned back to the outer environment by the RMPU. Temperature sensors are fitted inside the return air grill, to monitor the air temperature & react based on it. Melamine foam insulation covers all the duct to prevent water dripping by condensation due to exposure to the outside heat. DESCRIPTION FOR RMPU: The Roof Mounted AC Package Unit of LHB Coaches is a Microcontroller based unit developed to control the sub-systems of the RMPU automatically according to the Heating, Ventilation and Air-Conditioning (HVAC) algorithm to provide accurate



control thus resulting in comfort to passengers. (G). MOUNTING ARRANGEMENT: AIR DUCT:

All Air ducts shall be fabricated & brought into the coach as each separate sub-assemblies (10 Supply Air Ducts, Connector part, Connecting part, Compensation part, Return air Duct) etc.

Each duct is lifted to the roof and arranged in the order of the above given Duct arrangement drawing, after wrapping them around with Melamine insulation.

Return air ducts are fitted in the 4 corners of the coach.

Diffusers are fitted to the bottom of each sub duct.

L angle back pieces are welded below the diffusers on either side longitudinally, along the length of the coach, in passenger area.

Rubber Gasket is stuck to the bottom of the above back piece.

Aluminum Diffuser grills are then screwed to the back pieces. RMPU:

After Trough is fitted on the roof, the RMPU is lifted above the FRP trough.

All 4 corners of the RMPU have bolting arrangement.

These are fitted on the brackets provided in the shell on all 4 corners.

Make sure that ventilation area for Condenser Air Inlets and Condenser Air Outlets are not obstructed and condenser fans can rotate freely.

Also ensure that fresh air intake opening are not blocked or covered. 3.4 Ensure that the trap door and opening for the filters are not obstructed and that covers of these openings can be removed freely. 3.5

Also ensure that filters can be pulled out easily. 3.6 Connect thermostat and control panel to their respective matching terminals in the PAC unit.

Connect numbered power terminals of the PAC unit to respective numbered terminals in the control panel.

Re-check and tighten all screws, terminals, fuses and all control and power connections for their correctness. 3.8 Connect the power supply (415 V AC, 3 phases, 50 Hz) to the power input terminals.

(H). UNMOUNTING ARRANGEMENT: AIR DUCT:

The FRP panels located in the roof shall be unmounted first. After unmounting the FRP, the Aluminum Grill & its back pieces shall be

removed. From then, each sub assembled duct shall be brought down after removing the

rivets. Return air duct shall also be removed in the same manner.

RMPU:

All the bolts in the 4 corners shall be loosened and removed.

The RMPU should be lifted steadily using a lifting equipment and gently brought

down

(I). TOOLS REQUIRED:

Lifting Equipment

Spanner

Wrench

10mm box



(J). MAINTENANCE: RMPU:

Trip Attention: Remove dust and dirt from the panel.

Ensure that all the safety/protection devices are in the working condition and not in the by-passed condition.

Defective/by-passed components should be replaced.

Clean the filters if required. The defects noticed during the run should be attended monthly.

Remove dust and dirt and clean the panel completely with vacuum cleaner.

Remove the fresh air and return air filters. Replace them with pre-cleaned filters.

Run the plant for half and hour and check the current drawn by various equipment with the help of clamp tester.

Operation of safety cut-outs 7.2.1 OHP 1-2 Switch “ON” the heaters with blower off (take out blower fuses and short the vane relay terminals) Keep the package in manual heating mode.

The heaters should trip. 7.2.2 HP1-2 Switch “ON” the compressor with condenser fan OFF.

Take out the condenser fan motor fuses. Keep the package in manual cool mode. Compressor should trip in 3 minutes. HP cut-outs should be reset after each trip. CAMTECH/99/E/RMPU/1.0 25 Maintenance Handbook for Roof Mounted AC coaches July’1999 7.2.3 LP Cut-out (1-2) Switch “ON” the compressor and condenser with blower OFF. Take out the blower motor fuses and short the vane terminals (44-45).

Keep the package in manual cool mode. Compressor should trip in 3 minutes. SPP Create single phasing in compressor circuit by taking out the one fuse.

Compressor should trip and SPP RED LED should come on. Create single phasing in blower motor and condenser motor circuit by taking out one fuse. Motor should trip and O/L indication should come. Timer Check the timers for their operations. Timer 1 should have delay of 2 minutes and timer 2 should have a delay of 4 minutes.

Control PCB Keep the package in the auto mode.

Run the blower. Short points 3 & 4 on PCB. The compressor should come “ON”. Open the points 5 & 6, heater should come on.

Pour water into drip tray and ensure free flow. The defects noticed during the run should also be attended. Note: All the items of trip maintenance should also be carried out.

1.12 ASPIRATION BASED AUTOMATIC SMOKE AND FIRE DETECTION

SYSTEM (RDSO/SPEC/CG-04)

1.13 Operating Principle



Figure 24

The TITANUS ProSens Rail air sampling detection system is a fire detection system capable of early and very early fire detection. It is particularly suitable for areas in which point detectors cannot be used, or can only be used to a limited extent, where there are architectural limitations or where the risk of vandalism requires concealed installation A system of intake pipes with defined sampling orifices performs active air sampling and sends the results to the detector module. Here an intelligent signal processing system (tracking readings etc.) with a high- power light source (using light dispersion technology) evaluates the air samples and uses the parameters set in the detector module to generate an alarm. An alarm is signaled by a red LED and transmitted to the detection and alarm panel or the comms bus by means of a voltage-free alarm contact or relayed to the train bus system. The early fire detection happens at the point at which the fire first starts, the so-called pyrolysis phase. Signal processing using LogicSens can distinguish between a transient fault and an actual fire, which virtually rules out the risk of false alarms. In addition, there is the option of programming a specific time delay in the transmission of further alarms. The alarms are stored and can be reset after the cause has been established.

Active analysis or diagnosis logic enabling the supervision of the detector electronics guarantees that the system has a high level of operating reliability. Each detector module is monitored for contamination, faults and removal, as well as for the correct functioning of the implemented, unmodifiable firmware. Dirt on the detector module will have no effect on its sensitivity. The integrated active contamination detection allows for longer times between replacements. The system of intake pipes is monitored against faults such as pipe breakage, obstruction of the sampling orifices or fan failure, as well as blockage of an optional filter, by means of "Pipe Guard" airflow sensor technology.



1.13.1 Main Components

Figure 25

1.13.2 Inspections

These must be carried out approximately twice a year at roughly equal intervals. The inspections must cover the following critical functions: Test one detector in each carriage by triggering the system (e.g. with FlowCheck

test equipment or optional test adapter with test aerosols). Test one air sampling smoke detector in each carriage for faults by releasing the

air sampling pipe system or opening the optional test adapter or opening the cover of the optional air filter.

Visual inspection of the components for damage and pollution. Verify at the panel that the alarms produced are displayed, reset any active

alarms. Record and complete the inspection in the maintenance protocol.

1.13.3 Maintenance

To be carried out once a year. The inspections must cover the following critical functions See Inspections, and in addition: Test all detectors by triggering them (e.g. with Flow Check) Verify at the panel that the alarms produced are displayed, reset any active

alarms Record and complete the inspection in the maintenance log Note:

Maintenance activities include an inspection within their scope. An inspection



can therefore be omitted. When using an optional diagnostic tool, the actual state at the time of

maintenance can be logged.

1.13.3.1 Equipment/Kits for maintenance

Cleaning maintenance kit

Table 9

Figure 26

LHB Technological Development 6. Drawing Index

IRCAMTECH/GWL/MECH/2021-22/LHB/HB/1.0 Page 1

6. DRAWING INDEX

Version : 1.00







1.00 31/07/2021 First Release --



Table of Content

Amendment and Revisions .................................................................................................................. 2

Table of Content .................................................................................................................................. 3

AIR BRAKE SYSTEM AIR RESERVOIR 125L (KBIL) ................................................................................................................. 7

AIR RESERVOIR 75L .- (KBIL) ................................................................................................................ 8

DRAIN COCK ASSY. (FOR AIR RESERVOIR 200L)- (KBIL) ....................................................................... 9

AIR RESERVOIR 6L - (KBIL) .................................................................................................................10

AIR RESERVOIR 6L - (KBIL) .................................................................................................................11

HOSE WITH ADOPTER - (KBIL) ...........................................................................................................12

HOSE CONNECTION - (KBIL) ..............................................................................................................13

HOSE CONNECTION - (KBIL) ..............................................................................................................14

BRAKE PANEL MODULE-AC/NAC(EOG),ACCN(SG) - (FTIL).................................................................15

BRAKE PANEL MODULE-PC/SLR - (FTIL).............................................................................................16

C3W DISTRIBUTOR VALVE - (FTIL) ....................................................................................................17

INTEGRAL VOLUME RELAY WITH EP ASSIST - (FTIL) ..........................................................................18

C3W DV WITH INTEGRAL VOLUME RELAY –(CHARGING AND NORMAL RUNNING) - (FTIL) ............19

C3W DV WITH INTEGRAL VOLUME RELAY –(GRADUATED APPLICATION) - (FTIL) ............................20

C3W DV WITH INTEGRAL VOLUME RELAY –(GRADUATED RELEASE) -(FTIL).....................................21

PRESSURE SWITCH ASSY.-(FTIL) ........................................................................................................22

INTEGRAL VOLUME RELAY WITH EP ASSIST - (FTIL) ..........................................................................23

AIR RESERVOIR 125L .- (FTIL) .............................................................................................................24

AIR RESERVOIR 75L .- (FTIL) ...............................................................................................................25

CUT OFF ANGLE COCK WITH VENT .- (FTIL) .......................................................................................26

AIR BRAKE HOSE COUPLING FOR BP .- (FTIL) ....................................................................................27

AIR BRAKE HOSE COUPLING FOR FP.- (FTIL)......................................................................................28

DOUBLE BRAKE INDIACATOR ASSY..- (FTIL) ......................................................................................29

SINGLE BRAKE INDIACATOR ASSY.- (FTIL) .........................................................................................30

HOSE ASSY. ½”.- (FTIL) .......................................................................................................................31

HOSE ASSY.- (FTIL) .............................................................................................................................32

ISOLATING COCK 1”.- (FTIL) ...............................................................................................................33

PASSENGER EMERGENCY ALARM VALVE - 1.- (FTIL) .........................................................................34

PASSENGER EMERGENCY ALARM VALVE - 2.- (FTIL) .........................................................................35

ROLLER OPERATED 3 WAY VALVE.- (FTIL) .........................................................................................36

AIR RESERVOIR 75L .- (FTIL) ...............................................................................................................37

PULL BOX ASSY .- (FTIL) .....................................................................................................................38

INTER COACH CONNECTIONS.- (FTIL) ................................................................................................39



WIRING DIAGRAM .- (FTIL) ................................................................................................................40

CENTRAL/ END JUNCTION BOX .- (FTIL) ............................................................................................41

TEST BOX .- (FTIL) ..............................................................................................................................42

SEALED GANGWAY GANGWAY ASSEMBLY MOUNTING(1) – (HUBNER) ..........................................................................43

GANGWAY ASSEMBLY MOUNTING(1) – (HUBNER) ..........................................................................44

AUTOMATIC - INTERNAL SLIDING DOORS

ELECTRIC SCHEME FOR DOOR CABLE & DOOR LEAF – (PARS COMPONENTY) .................................45

ELECTRIC SCHEME FOR MECHANISM – (PARS COMPONENTY) ........................................................46

ELECTRIC SYSTEM SCHEME – (PARS COMPONENTY) ........................................................................47

INTERNAL SLIDING DOOR – (PARS COMPONENTY) ..........................................................................48

VACUUM BIOTOILET

ELECTRICAL SCHEME DIAGRAM – (AMIT ENGINEERS) ......................................................................49

PNEUMATIC AND WATERLINE DIAGRAM – (AMIT ENGINEERS) .......................................................50

PNEUMATIC SCHEME DIAGRAM – (AMIT ENGINEERS) .....................................................................51

GENERAL

LAYOUT OF AC THREE TIER EOG ........................................................................................................52

GENERAL INSTALLATION FOR LHB AC THREE TIER EOG ....................................................................53

GI OF LHB POWER CAR FOR HUMSAFAR COACH (WITH PLUG DOOR) .............................................54

LAYOUT OF SECOND CLASS AC CHAIR CAR EOG ...............................................................................55

GENERAL INSTALLATION OF SECOND AC CHAIR CAR (EOG) .............................................................56

LAYOUT OF EXECUTIVE CLASS AC CHAIR CAR (EOG) ........................................................................57

GENERAL INSTALLATION OF EXECUTIVE CLASS AC CHAIR CAR (EOG) ..............................................58

GENERAL INSTALLATION OF LHB EXECUTIVE CLASS AC CHAIR CAR (EOG) .......................................59

GENERATOR CUM BRAKE VAN COMPLETE .....................................................................................60

LAYOUT OF HIGH CAPACITY PARCEL VAN WITH LUGGAGE RACKS ...................................................61

GI OF LHB HIGH CAPACITY PARCEL VAN WITH COLLAPSIBLE DOORS AND LUGGAGE RACKS ..........62

LAYOUT OF LHB POWER CAR 200KMPH WITH AUTOMATIC DOORS ...............................................63

LAYOUT HIGH CAPACITY DOUBLE DECKER LHB AC CHAIR CAR (120 SEATER) ..................................64

GI FOR DOUBLE DECKER LHB AC CHAIR CAR (120 SEATER) ..............................................................65

LAYOUT HIGH CAPACITY DOUBLE DECKER LHB AC CHAIR CAR (104 SEATER) ..................................66

GI FOR DOUBLE DECKER LHB AC CHAIR CAR (104 SEATER) ..............................................................67

GI OF LHB POWER CAR FOR DOUBLE DECKER (UDAY) COACH ........................................................66

CONNECTION CAR BODY BOGIE ........................................................................................................69

CONNECTION CAR BODY BOGIE ........................................................................................................70

INTERCAR GANGWAY MOUNTING ....................................................................................................71

ARRANGEMENT OF FIRE EXTINGUISHER AND WATER PURIFIER ......................................................72

BOGIE GENERAL ARRANGEMENT FOR NON AC COACH....................................................................73



COACH FLOOR COMPLETE FOR GS (EOG) 100 SEATER COACH .........................................................74

FIXING ARANGEMENT WATER TANK FLAP FOR LHB TYPE GS ...........................................................75

LAYOUT OF WINDOWS FOR GS COACH ...........................................................................................76

FIXING ARANGEMENT OF LUGGAGE RACKS SINGLE SEAT SIDE ........................................................77

SUPERSTRUCTURE PAINTING OUTSIDE FOR GS (EOG) (ANTHYODAYA) ...........................................78

ELECTRICAL EQUIPMENT MOUNTING – UNDERFRAME FOR SCN & GS EOG COACH .......................79

STEP COMPLETE MOUNTING ............................................................................................................80

COUPLER MOUNTING .......................................................................................................................81

TRANSFORMATOR MOUNTING .........................................................................................................82

LAYOUT OF PARTITION FRAME LWS/EOG 100 SEATER COACH ANTYODAYA ...................................83

GRIPS, LABEL MOUNTING ARRANGEMENT FOR LWS COACH (LHB TYPE) ........................................84

LOCATION OF PANELLING AND MOULDING OF SIDE WALLS ANTYODAYA ......................................85

LOCATION OF DOORS FOR LWS (EOG) ANTYODAYA .........................................................................86

SEATING ARRANGEMENT OF LWS (EOG) ANTYODAYA .....................................................................87

SEATING ARRANGEMENT OF LWS (EOG) ANTYODAYA .....................................................................88

SANITARY FACILITIES ANTHODAYA ...................................................................................................89

LAYOUT OF LETTERING INSIDE GS (EOG) ..........................................................................................90

SUPERSTRUCTURE PAINTING OUTSIDE LWS (EOG) (ANTHYODAYA) ................................................91

MARKING DIAGRAM FOR LWS EOG (ANTYODYA) ............................................................................92

LAYOUT OF LWS (EOG) 100 SEATER ANTHYODAYA ..........................................................................93

GI OF LWS (EOG) 100 SEATER ANTHYODAYA ....................................................................................94

WATER PURIFIER AND MOUNTING FOR SCN LHB TYPE ....................................................................95

SEAT DETAILS FOR VISTADOME COACH ............................................................................................96

LUGGAGE RACK MAIN VISTADOME COACH ......................................................................................97

RUBBER FLOORING CONCEPT VISTADOME COACH ..........................................................................98

END WALL FRAME COMPLETE VISTADOME COACH ........................................................................99

LOCATION OF SIDE WALLS VISTADOME COACH .............................................................................100

OUTLINE DRAWING FOR SIGNAGE – TOILET VISTADOME COACH ..................................................101

WIRING DIAGRAM FOR OPALSCENCE ROOF WINDOW VISTADOME COACH .................................102

OUTLINE DRAWING FOR SQUARE DOWN LIGHT VISTADOME COACH ...........................................103

OUTLINE DRAWING FOR LINEAR LIGHTING VISTADOME COACH ...................................................104

INTERIOR GRILL ASSEMBLY VISTADOME COACH ............................................................................105

SWITCHABLE GLASS VISTADOME COACH .......................................................................................106

PIPE CONNECTION TO AUX ROOF WATER TANK VISTADOME COACH ...........................................107

MOUNTING ARRANGEMENT AIR INLET DUCT VISTADOME COACH ...............................................108

PANTRY LAYOUT VISTADOME COACH ............................................................................................109



THIS PAGE IS INTENTIONALLY LEFT BLANK

CLOSE ( 1 : 10 )

A ( 1 : 2 )

B ( 1 : 2 )

C-C ( 1 : 2 )

D-D ( 1 : 2 )

E ( 1 : 2 )

F-F ( 1 : 2 )

G-G ( 1 : 2 )

L CLOSE ( 1 : 20 )

L OPEN ( 1 : 20 )

H-H ( 1 : 2 )

A

B

C

C

D

D

E

F

F

G G

H H

Dokum

ent je obchodním

tajem

stvím

Pars Kom

ponenty s.r.o. Užití,

rozšiřování nebo rozm

nožování je m

ožné pouze se souhlasem

této

organizace. Příjem

ce je odpovědný za škody vzniklé zneužitím

Technol.

Název

Sv.dozor

Rozměr

Materiál

Dok. kontrolySchválil

Číslo výkresu

TDP

Index

Listů

List

Měřítko

St.v.

Hmot.

T.O.

Norma

Ind. Poč. Změna PodpisDatum Poz.Užito u č.v.sestavy

Tolerance

Vypr.

Formát

DVEŘE INT. POSUVNÉ

110VDC, L, P

1.0291.36.01.0

-

Fiala 7.11.2018

50,156 kg

1 : 10

A1

1

1

Lep.dozor

1.0291.36.02.0

ČSN ISO 2768-mK

(143,2)

1609,2

1466

1426

30

(32)

121,5

(149)

(166)

65

1953

11

11

895,5

12

16

19

1

16

18

SEŘÍDIT DVEŘNÍ KŘÍDLO

POMOCÍ KRAJNÍCH ŠROUBŮ

POZ. 16 S EXCENTRY, POTÉ

ZAJISTIT VŠECHNY ŠROUBY

VČETNĚ PROSTŘEDNÍCH

UTAHOVACÍ MOMENT ŠROUBŮ

DVEŘNÍHO KŘÍDLA Mu= 29 N.m

TO SET THE DOOR WING

USING SIDES SCREWS

POS. 16 WITH EXCENTR,

THEN ENSURE ALL SCREWS,

INCLUDING MIDDLE SCREWS

TIGHTENING TORQUE OF THE SCREWS

ON DOOR WING Mu = 29 N.m

38

2

369 9696

2

33

26

35

1

15

18

14

19

41 40

13

17

(2119)

KABEL Z KŘÍDLA PROTÁHNOUT

ENERGO ŘETĚZEM NA MECHANISMU,

PŘIPEVNIT STAHOVACÍMI PÁSKAMI

A ZAPOJIT DO SVORKOVNICE

9

0

°

9

0

°

(66)

(82)

(135)

(88)

(66)

3,5

-01,5

+

81

25

1

12

16

18

33

35

8

3

2 38

1.0291.36.01.0

PROVEDENÍ LEVÉ

1.0291.36.02.0

PROVEDENÍ PRAVÉ

1:10

1 15 18

14 19

15

(SEŘÍZENÍ MECHANISMU V ZÁSTAVBĚ NORNÍMI ŠROUBY

POZ. 15 S EXCENTRY A POTÉ DOTÁHNOTU VČETNĚ

ZAJÍŠŤOVACÍCH ŠROUBŮ POZ. 14)

(ADJUSTMENT OF THE MECHANISM IN THE FOUNDRY OF THE NORMAL SCREW

POS. 15 WITH EXCENTRATIONS AND NON-CONTRIBUTORS INCLUDING ENSURE

REPLACING SCREWS POS. 14)

5

UMÍSTĚNÍ VÝROBNÍHO ŠTÍTKU

PLACE OF MARKING

60 60

44

1

15

18

M8x1.25 - 6g

90,5

14

19

26 26

52x(600)

288162 138

41 40

13

17

15MIN.

801

825MAX.

UTAHOVACÍ MOMENT ŠROUBŮ DVEŘNÍHO KŘÍDLA Mu= 29 N.m

TIGHTENING TORQUE OF THE DOOR WING SCREW Mu = 29 N.m

8

LEFT DOOR

RIGHT DOOR

CYLINDER CABLE PULL BY

ENERGO MECHANISM CHAIN,

SECURE BY TIGHTENING STRIPS

AND SWITCH WITH ELECTRICAL TERMINAL BLOCK

LHB Technological Development 7. General Information

IRCAMTECH/GWL/MECH/2021-22/LHB/HB/1.0 Page 1 of 5

7. GENERAL INFORMATION

Version : 1.00







1.00 31/07/2021 First Release --



Table of Content

7. GENERAL INFORMATION ..................................................................................................... 1

Amendment and Revisions .................................................................................................................. 2

Table of Content .................................................................................................................................. 3

7.1. QUALITY OF COMPRESSED AIR ............................................................................................ 4

7.2. QUALITY OF WATER ............................................................................................................. 5

7.3. TRANSPORTATION CODE ..................................................................................................... 5

7.4. EXTERNAL SUPPLY ............................................................................................................... 5

7.5. ABBREVATIONS .................................................................................................................... 5



7.1. QUALITY OF COMPRESSED AIR

Quality of compressed air: ISO 8573-1

Definition for solids: 5 μm Maximum particle size 5 mg/m3 Maximum concentration Definition for water: 3°C Maximum pressure dew point Definition for oil: 1 mg/m3 Maximum content

~0,8 ppm Maximum concentration

Illegal impurity: PAO-/Ester-oil, antifreeze, alcohol

Other impurity test on compatibility.

Contaminants in compressed air

Compressed air quality according to IS0 8573-1

Definition for solids Definition for water

Definition for oil

IS0Class

Maximumparticle size[μm]

Maximum concentration[mg/m3]

Maximum pressuredew point[°C]

MaximumContent[mg/m3]

MaximumConcentration[ppm]

1 0,1 0,1 -70 0,01 ~0,01

2 1 1 -40 0,1 ~0,1

3 5 5 -20 1 ~0,8

4 15 8 3 5 ~4

5 40 10 7 25 ~20

6 -- -- 10 -- --

The values are defined at pressure = 0 bar, 20 °C, 60 % rel. humidity.



7.2. QUALITY OF WATER Low degree of hardness

Part of bacteria as minimum as possible

7.3. TRANSPORTATION CODE

Coach Name Type Unique Transportation Code

Tejas Executive AC chair car LFCZAC

AC Chair Car LSCZAC

Humsafar AC 3 Tier Coach LWACCNH

Vista Dome Executive AC chair car LWCTZAC

Uday (Double Decker) Chair Car LWSCZDAC

High Capacity Parcel Van Parcel Van LVPH

Antodaya GS Coach LWS

7.4. EXTERNAL SUPPLY

AC equipment can also be operated by external 415 V AC supply.

7.5. ABBREVATIONS

ASU Air Supply Unit

ASP Air Suspension Pressure

AQS Air Quality Sensor

CCTV Closed Circuit Television

CFS Choked Filter Sensor

DDB Digital Destination Board

EOG End On Generator Car

HDD Hard Disk Drive

KB Knorr Bremse

LED Light Emitting Diode

LCD Liquid Crystal Display

NVR Network Video Recorder

PICCU Passenger Information and Coach Computing Unit

PC Power Car

PIS Passenger Information System

POE Power Over Ethernet

SSD Solid State Drive

TODS Toilet Odour Detection System

TASI Toilet Annunciation Sensor Interface

USB Universal Serial Bus

VFS Ventilation Fan Sensor

WAP Wireless/Wi-Fi Access Point

WSN Wireless Sensor Network

LHB Technological Development 8. Trouble Shooting


Page Page 1 of 24

8. TROUBLE SHOOTING

Version : 1.00


Content in this document is compiled with the inputs provided by ICF, MCF, RCF and OEMs.



Page Page 2 of 24



1.00 31/07/2021 First Release --



Page Page 3 of 24

Content

8. TROUBLE SHOOTING ........................................................................................................... 1

8.1. VACUUM BIO TOILET ( Amit Engineers) .............................................................................. 4

8.2. VACUUM BIO TOILET ( Oasis ) ............................................................................................. 5

8.3. Fire Detection & Alarm ( Sanrok) ........................................................................................ 5

8.4. Fire Detection & Suppression ( Fogtech) ............................................................................. 8

8.5. Sealed Gangways (Hubner) ................................................................................................. 8

8.6. Axle Mounted Disc Brake System (Knorr Bremse) .............................................................. 9

8.7. Axle Mounted Disc Brake System (FAIVELEY TRANSPORT) ............................................... 15

8.8. Smart Coach (APAUL INSTRUMENTS)................................................................................ 19

8.9. Automatic Hinged Door (BONY/IMI) ................................................................................. 21

8.10. Infotainment System (FUNTORO) ..................................................................................... 22

8.11. Water Level Indicator ( Amit Engineering) ........................................................................ 23

8.12. SEAT -180 DEGREE ROTATABLE (VISTADOME) .................................................................. 24

8.13. ELECTRICALLY CONTROLLED OPALESCENCE – ROOFTOP (PrivaLite) ................................. 24



Page Page 4 of 24

8.1. VACUUM BIO TOILET ( Amit Engineers) S.No Error/Fault Check Point Action Required

1 AIR FT (Air

Fault)

Check if proper air supply is available or not

Also check if air pressure is within the working range of 4 to 6 bar.

Provide proper air if not available

2 WATER LOW

Check if proper water supply is available or not

Also check if water pressure is within the working range of 0.05 to 1.5 bar.

Provide proper water if not available

3 BOWL FLOOD Check if the water flooding in the pan is due to blockage in pan or

pipeline.

If solenoid is not working replace the block

If foreign material is stuck in toilet line, use Soft Reverse Cycle by pressing S1, S2 & S3 button simultaneously on controller for 3 seconds.

If the blockage is not cleared, then use Hard reverse cycle by pressing S1, S2 & S4 button simultaneously on controller for 3 seconds and confirmation by service Laptop.

4 Ejector Choked

Check Ejector & Ejector valve for any blockage

Cleaning of Ejector and ejector valve is required

5 Chocking

Check if pinch valve 2 solenoid is working normally or not(It

should be Normally open ) and check if there is any blockage in

the toilet line

If solenoid is not working replace the block

If foreign material is stuck in toilet line, use Soft Reverse Cycle by pressing 51, S2 & S3 button simultaneously on controller for 3 seconds.

If the blockage is not cleared, then use Hard reverse cycle by pressing S1, S2 & S4 button simultaneously on controller for 3 seconds and confirmation by service Laptop

For details, kindly refer – Technical Manual for vacuum evacuation toilet system by Amit Engineers (December 2018)



Page Page 5 of 24

8.2. VACUUM BIO TOILET ( Oasis ) S.No Error/Fault Action Required

1 Valve fails to operate

1. Check electrical supply with voltmeter. Voltage must agree with nameplate rating.

2. Check coil with ohmmeter for shorted or opened coil. 3. Make sure that pressure complies with nameplate

rating.

2

Valve is sluggish or inoperative—electrical

supply and pressure check out.

1. Disassemble valve; clean out extraneous matter. The plunger must be free to move without binding.

2. If a diaphragm design, check the diaphragm for tears and/or clogged or obstructed bleed hole or pilot orifice. Torn diaphragm must be replaced.

3. Check all springs. If broken, replace.

3 External leakage at

sleeve flange or joint between body and cover

Check that the sleeve and/or cover screws are torqued to specifications. If leakage persists, replacement of diaphragm assembly or flange O-ring may be required and/or bodies or covers with damaged sealing surfaces may have to bereplaced.

4 External leakage at

speed control device Check O-rings for damage and replace if necessary.

5 Internal leakage

1. Disassemble valve, remove extraneous matter, and clean parts in a mild soap and water solution.

2. Examine diaphragm sealing surface for dirt. Remove all foreign particles. Examine orifice for nicks. Damaged parts must be repaired or replaced.

3. Check plunger return spring. Replace if broken.

6 Chatter or buzz sound

when energized

1. Remove power from the coil. 2. Inspect the plunger and sleeve for excessive wear or

contamination.

8.3. Fire Detection & Alarm ( Sanrok)

S.No Description Action

Required Remark

1

Power Supply unavailable

Check Power, Indication-1 and Indication-2 are on if not

Switch on the main MCB to provide supply to Panel.



Page Page 6 of 24

Report if you find that power supply is not working or in damage condition.

2

Hooter, Flash Light and Speaker not working

Report if you find it is missing or damage in coach

4

Check following test in the coach by connecting Vesda Panel with HLI and Computer and note

reading as defined. (Please refer Sanrock-Manual ).

a. Raw air flow(1400-1600) b. Filter Life(0-741 days) c. Air flow(100% +/- 20)

Report if there is any devaition from the standard reading

HLI cable is required to connect the system with

computer

5 Smoke not detected sampling point in coaches.

(refer picture) Flush Pipe

network by



Page Page 7 of 24

using air blower at inlet of pipe from filter area

and each sampling point

in coaches. (refer picture)

6

Fault in panel.

Observe if fault(yellow light) is coming in panel.

Report if your find fault light in the Panel.

7

Position of Isolation Cock is isolated.

Position of Isolation Cock in Coaches. It should be in open condition and if there is any problem with the system. Ensure to isolate the coach with the system so that train can move further.

Report immediately with coach number and location to resolve issue.



Page Page 8 of 24

8.4. Fire Detection & Suppression ( Fogtech) S.No Error/Fault Cause Action Required

1 Fire Detection & suppression system failed

Break in circuit.

Short-circuit.

Detector missing or defective.

Terminal clamp defective.

End resistor on line: missing or incorrect value.

Rectify the mentioned Causes

8.5. Sealed Gangways (Hubner)

Main assembly group Possible failure Inspection method Action

Corrugated bellows, assy.

Tears or holes in fabric

Broken bellows frame

Bellows fabric torn

out of bellows frame

Sealing/gluing of screw-on frame is not tight

Visual inspection

Visual inspection

Visual inspection

Visual inspection

Repair according to OEM instructions.

Repair according to OEM instructions.

Repair according OEM instructions.

Renew sealing



Page Page 9 of 24

Bridge plate, assy. (upper)

Sluggishness of rod hinge

Upper bridge plate

does not rest correctly on lower bridge plate

Sliding ledge

worn / damaged

Functional check by moving the flap up and down

Visual inspection

Visual inspection

Cleaning/lubrication of rod hinge (e.g. using oil spray)

Cleaning/repair resp. replacement of affected component

Replace sliding ledge

Bridge plate, assy. (lower)

Sluggishness of rod hinge Functional check by moving the flap up and down

Cleaning/lubrication of rod hinge (e.g. using oil spray)

Corrugated bellows, assy.

Dirt and garbage accumulated on corrugated bellows' floor

Visual inspection by flipping-up bridge plates into vertical position

Cleaning, e.g. with industrial vacuum cleaner

8.6. Axle Mounted Disc Brake System (Knorr Bremse) S.No Error/Fault Cause Action Required

Brake Hose Coupling

1 Leakage from coupling head

joint.

Grooved ring dirty or damaged, not sealing

Change the groove ring

2 Leaking brake hose coupling

Brake hose damaged

Hose clamp (2) Loose

Remove the unit, arrange for its chang-ing the hose / clamp as required

3

Brake hose coupling

refuses to Couple

Palm ends of the coupling head damaged

Remove the unit, arrange for changing of defective coupling head its disposal*

and exchange for an operative unit

Indicator AZ7

1

Only partial or no change of display when

pressure is admitted

Air pipe connection leak-ing.

Tighten the connections (apply the specified tightening torque!) and test

for leakage.

2

Display not returning to its home position when pressure

is vent-ed.

Unit defective Remove the unit and submit for repair

Check Valve

1 Air discharging constantly be-

tween unit Fastener loose

Tighten the fasteners and test for leak-age; observe the specified tightening

torque.



Page Page 10 of 24

and base plate O-rings defective

Remove the unit, exchange the seals, install the unit and test for leakage

2 Air discharging

constantly from the unit

Unit defective Remove the unit and organize for

repair. 3

Air reflux through the

unit

STOP COCK DH7-TE

1 Unit is hard to

operate Camshaft , valve tappet or valve head sticking

Operate the unit few times; remove the unit if still not working.

2

Air discharging constantly

between unit from the

flange surface

Fasteners loose Tighten the fasteners (observe the

tightening torque) and test for leak-age.

O-rings damaged or missing

Replace the new O-rings & install the unit.

3

Air discharging constantly from the housing

Unit defective Remove the unit and organize for the

replacement.

4


from port A1 or A2

(provided the unit is func-

tioning properly, air may escape

briefly just to vent A3)

STOP COCK AHB

1


between unit from the

flange surface.

Fasteners loose Tighten the fasteners (observe the

tightening torque) and test for leak-age.

O-rings damaged or missing

Replace the new O-rings & install the unit.

2 Motion of rotation is

tight

Damaged ball, seals, bolt.

Remove the unit and organize for the replacement

3

Passing of compressed

air through the isolating position.

Damaged seal, possibly ball.

Remove the unit and organize for the replacement

PRESSURE GOVERNOR



Page Page 11 of 24

If the unit starts to malfunction, trace possible problems on board. Causes of problems can be corrected with the help of the directions proposed for debugging

TEST FITTING K1-E

1

Compressed air discharging

con-stantly between unit and mounting

bracket or pipe

O-ring (g) defective Remove the unit, exchange the seal, in-stall the unit and test for leakage.

Unit loose Release the unit, screw tight again

(apply the specified tightening torque) and test for leakage.

2

Air discharging at the end

with the test connection

when the cap is removed

Unit defective Remove the unit, install a new unit and

test for leakage

3

Pressure measurement reveals an air

pressure differing from

P

ROLLER LEVER VALVE WITH AN EXHAUST

1 Port A not

being charged No compressed air at

port P Connect the supply of compressed air

to port P.

2

No change at port A when

the unit shuttles

Unit defective Remove the unit, arrange for its

disposal and exchange for an operative unit.

3

Compressed air discharging from port P or

A

Connections leaking Tighten the connections (apply the

specified tightening torque!) and test for leak-age.

4


con-stantly from the unit in the region around valve

Unit defective Remove the unit, arrange for exchange

for an operative unit.



Page Page 12 of 24

tappet (a)

5


con-stantly from exhaust R (regardless of the unit's

working position)

PRESSURE GAUGE 80X10

1 False pressure

readings

Bulb/LED (f) defective Exchange the bulb/LED.

Leaking pipe union (P) Tighten union nut (c) (apply the

specified tightening torque!) and test for leakage.

Unit defective Remove the unit and exchange for an

operative unit.

2

Pointer not moving

although pressure is changing

Connection from system to pres-sure gauge is interrupted/cut off

Check and restore the connection

Unit defective Remove the unit and exchange for an

operative unit.

Isolating Cock G1-DN25E

1 Unit

Inoperative Handle not in end position

Move handle to end position.

2 Air discharging

constantly from threaded

Threaded ports leaking Tighten the threaded connections

(apply the specified tightening torque!) and test for leakage.



Page Page 13 of 24

port P1 and/or P2

3 Ball cock with an exhaust is not venting

Exhaust port 0 clogged Clean out the exhaust port 0

Through-hole D in isolating ball (a) is

clogged

Remove the unit, arrange for its dis-posal and exchange for an operative

unit.

4

A ball cock with-out an exhaust is

leaking from the exhaust

port in the cut off position

Core stopper fitted incorrectly

5

Compressed air present at outlet port P2 in the cut off

position

Moulded sealing ring (e1) ) and/or counter-support (e2) defective

6


from control shaft (c)

0-ring (f) defective

EMERGENCY BRAKE VALVE NB12A

1


from exhaust port

Valve seat V dirty and/or damaged, or valve

sealing ring of piston rod defective

Repair the emergency brake valve in accordance with relevant sections.

2

Provided the emergency

brake valve is functioning

correctly, air must

discharge abruptly when the emergency brake valve is

operated.

Piston rod jammed

Compression spring defective

3

Brake pipe L not being

vented when the emergency brake valve is

operated

Piston rod jammed

Bores and orifices in piston rod and/or

screwed choke clogged



Page Page 14 of 24

EMERGENCY BRAKE PULL BOX

1

Unit not venting when

handle is pulled, or no compressed air ap-plied after reset

Unit not being activated pneumatically

Test the unit for correct pneumatic control.

Unit defective Remove the unit and submit for repair

2

Snap-action switches not thrown when

handle is pulled or after

reset is completed

Unit not being activated electrically

Check the cable connections.

Test the unit for correct electric control

Unit defective Remove the unit and submit for repair.

3 Compressed

air discharging from port

Connection leaking Tighten the connection, apply the

specified tightening torque and test for leak-age

4


constantly from the

exhaust port. Unit defective Remove the unit and submit for repair

5 Unit cannot be

reset

BRAKE CALLIPER UNITS

1

Incorrect brake shoe clearance S

after repeated braking

The brake cylinder application stroke is not the length required for the caliper transmission

Correct the application stroke as described in the Overhaul Instruc-tions

valid for the brake cylinder

2

Little or no brake shoe clearance S after new

brake pads have been

fitted

Adjusting spindle of brake cylinder is not

entirely reset

Screw the adjusting spindle of brake cylinder a back home with the reset

nut R.

STEEL BRAKE DISC (640/350X110-20)

1 Scorch marks appearing on the friction

The brake pads consist of an unsuitable

material Install brake pads of the specified kind.



Page Page 15 of 24

ring The onboard brake control unit is possibly

defective

Check the brake control unit, ex-change or submit for repair

The values allowed for wobble or parallel

misalignment will be exceeded

Trace and correct the causes

The brake pads are defective due to

overheating

Trace and correct the cause of over-heating, exchange the brake pads

2 Chattering

during brake application

The values allowed for wobble or parallel misalignment are

exceeded

Face off the friction rings

3 The friction

ring surface is damaged

The brake pads are severely worn, or brake application takes place

without pads

Depending on their condition, face off the friction rings or exchange the

friction rings and brake pads

4 The friction disc is loose

Possible loss of bolt pre-tensioning force

Notify KNORR BREMSE. Tighten the fastener

8.7. Axle Mounted Disc Brake System (FAIVELEY TRANSPORT) S.No Error/Fault Cause Action Required

CONTROL RESERVOIR ALONE AT 5 Kg/cm2

1

Leak at Exhaust Ring Protector .

In the Main Valve Lip Seal in the Lower Cover is defective or fixed upside down.

Replace the Lip Seal or assemble correctly.

2

Leak at Quick Release Chamber Outlet

Lip Seal in the Cover of Quick Service Bulb defective or fixed upside down.

Replace or assemble correctly.

3

Leak back to the Brake Pipe, when the Brake Pipe pressure is reduced

Surface condition of Valve in the Cut-off valve defective.

Replace the valve

Spring wrapped. Replace.

Diaphragm or Diaphragm defective or wrongly assembled.

Replace or relocate

'0' Ring defective or twisted

d. Replace or relocate.

4

Leak at the Release Valve Lever

Surface condition of Valve defective in Double Release Valve (the one on the opposite side of the flange)

Replace the valve and attend.

5 Leak to Wrongly assembled diaphragm

Relocate the diaphragm.



Page Page 16 of 24

atmosphere at the Hole (s) in the bottom cover, under Brake Cylinder reaction pressure.

'0' Ring between body and lower cover defective

Replace '0' Ring

6 Leak to the Brake Cylinder.

'0' Rings and defective. a. Replace.

7

External leakage between Lower Cover and Body or between Cover and Body.

Diaphragm or wrongly

assembled.

Relocate

'0' Rings between lower

Cover and Body

defective.

Replace

8

External leakage to atmosphere from the Auxiliary Reservoir

Sealing Ring (20) defective.

Replace.

AUXILIARY RESERVOIR ALONE AT 5 Kg/cm2

1

Leak back to Brake Pipe when the Brake Pipe pressure is decreased.

Surface condition of the

Valve defective.

Replace.

2

Leak at the Release Choke

Condition of Valve

defective.

Replace.

'0' Ring of Valve twisted

or defective.

Relocate or replace '0' Ring.

3

Leak to atmosphere under reaction to Brake Cylinder pressure.

'0' Ring between Body

and Cover defective.

a. Replace.

4 Leak at Release Valve at the bottom.

Surface condition of

Valve defective.

Replace.

5

External Leakage defective.

'0' Ring(s) between Body

and Cover and between

Body and top Cover

defective.

Replace.

Metallic joints between

Body and Caps

Unscrew Caps and apply the Sealing grease and fix again.

Sealing Ring defective.. Replace

BRAKE CHARGING, BRAKE PIPE AT 5 Kg/cm2



Page Page 17 of 24

1 Filling time of the Reservoirs too short

Valve does not close. Reassemble the entire Cut off valve sub assembly

2 Springs are wrapped or

tangled up.

if wrapped, replace and reassemble properly.

3 Spring Seats jammed. Replace if damaged and reassemble.

4 Vibrations while charging

'0' Ring defective. a. Replace.

5 Filling time of the Reservoirs too long.

The Solex Jet is clogged

partly.

Clean the orifice.

BRAKE CHARGED BRAKE PIPE AT 5 Kg/cm2

1

Leak at the Quick Release chamber outlet.

Surface condition of

Valve defective.

Replace

Seal in Seal Holder

assembled upside down

are defective.

Assemble properly or replace.

‘O’ Ring are twisted or

damaged.

Relocate or replace.

2

Leak to atmosphere under reaction of Brake Cylinder pressure

Seal in Diaphragm Holder

wrongly positioned or

defective.


O’ Ring defective on

Diaphragm Holder

Replace.

Diaphragm wrongly

assembled or defective.


INSENSITIVITY

1

Brake Pipe pressure drop too slow, accompanied by drop in pressure in Auxiliary Reservoir.

Improper closing of Valve Check the surface condition and if required replace.

2 Brake Pipe pressure drop too quick

Improper closing of the

Quick Release bulb inlet

Valve thus allowing

partial filling of the Quick

Service Bulb.

Check the surface condition and if required replace.

3 Quick action in Brake Pipe while brake releasing.

Improper closing of valve Same as above.

Valve of Cut-off Valve

does not open. Same as above.

Springs tangled up. Assemble properly.

SENSITIVITY



Page Page 18 of 24

1 No quick

action.

Valve improperly

functioning. Check, relocate or replace.

Valve not closing

properly due to defective

surface of the defective

spring

Check, relocate or replace.

Faulty assembly of quick

service valve complete Open fully (Quick service valve) and reassemble properly

BRAKE APPLICATION STEP, BRAKE PIPE AT 5 Kg/cm2

1

Full brake

application

with large leak

to atmosphere

under pressure

of brake

cylinder.

Diaphragm improperly

assembled. Reassemble.

2

Full brake

application

with no leak.

Atmosphere leak hole

clogged with dirt. Open bottom Cover and clean hole.

BRAKE APPLICATION BRAKE PIPE AT ‘0’ PRESSURE

1

Application

time less than

3 secs.

Leak around the threads

of choke Unscrew and apply the sealing grease and retighten.

Improper closing of valve

or delayed closing. Check valve surface condition. If defective replace.

Leak at metallic joints of

Plug. Unscrew and apply sealing grease. Retighten properly.

‘O’ Ring of Plug

defective. Replace.

2

Application

time exceeds 5

secs.

Choke partially

blocked/clogged. Clean Choke.

Valve closing too soon. Check the whole Inshot Valve Assembly.

3 Leak at Release

Choke.

Defective surface

condition of Valve. Replace Valve.

4

Leak hole to

atmosphere

under reaction

of brake

cylinder

pressure.

Diaphragm of Main Valve

incorrectly. Relocate or replace.

Defective ‘O’ Ring Replace.

5 Leak at the

Quick Service

Seal of the Quick Service

Outlet incorrectly Relocate or replace.



Page Page 19 of 24

Chamber

outlet.

assembled or defective

6

Leak at the

Cut-off Valve

Cap .

Seal improperly

assembled or defective. Relocate or replace.

7

Leak at the

Inshot Valve

Cap

Diaphragm of Inshot

improperly assembled

or defective.

‘O’ Ring (226) defective.


Replace

BRAKE RELEASE BRAKE PIPE AT 5 Kg/cm2

1

Release time

less than 15

secs

Leak around Release

Choke .

Open Exhaust Protector remake the joint with sealing grease. Also open

screw, remove Choke, apply grease on threads and retighten.

8.8. Smart Coach (APAUL INSTRUMENTS) S.No Error/Fault Action Required

1 POWER ISSUE Voltage should be 110 VDC/ AC at input and 24V DC at output end check it through the multimeter. If issues are not resolved then contact service engineer.

2 7” TOUCH DISPLAY Check the touch of the unit if it is not working then contact service engineer.

3 GPS

Check the led of the PICCU system if it is green it means it is in working condition. If it is red then check SMA connector of antenna and connection if issues are not resolved then contact service engineer.

4 GSM

Check the led of the PICCU system if it is green it means it is in working condition. If it is red then check SMA connector of antenna and connection If issues are not resolved then contact service engineer.

5 SSD

SSDs should be mounted properly. To check go to the information section then enter in memory. Screen will show the SSD Information details. If issues are not resolved then contact service engineer

6 CAMERA If the camera is not working then check M12- 8 pin connector at PICCU end. If issues are not resolved then contact service engineer.

7

WAP POWER

If WAP is not powered up then you should check voltage . Voltage should be at the power connector 24 V check it through the multimeter. If issues are not resolved then contact service engineer

WAP COMMUNICATION

If the Info entertainment app is not in working condition then check LAN cable connection at WAP. It should be Issue of loose cable. If issues are not resolved then contact service engineer.

8 LCD COLOUR LCD has black background & white font at the display if



Page Page 20 of 24

display shows different colour ,then there is an issue of VGA cable connection there may be a loose connection at display or at PICCU/NVR/CCU or may be VGA cable broke away from the connector DB15. If issues are not resolved then contact service engineer .

9 LCD POWER

IF LCD is not powered up then you should check voltage at the connector of the LCD. Voltage should be at power connector 110V DC. If issues are not resolved then contact service engineer

10 LCD SIGNAL

If LCD shows nothing / blank screen .There may be an issue of power / loose connection of VGA connector. Switch off the power of LCD & switch on, if LCD shows no signal block then it is an issue of loose connection of VGA connector otherwise it is an issue of power check voltage at power connector of LCD If issues are not resolved then contact service engineer

11 DDB COMMUNICATION

If DDB shows only “Indian railways welcomes you” in Hindi & English then there may be an issue of communication signals. To test communication signals from PICCU to DDB you should enter in route selection and select route at PICCU. If DDB doesn’t show the messages then check the RS485/WAP connector. If issues are not resolved then contact service engineer

12 PICCU POWER

IF PICCU is not powered up then you should check voltage at WAGO connector comes from terminal board and fuse also. Voltage should be at power connector 110V. If issues are not resolved then contact service engineer

13 AUDIO OUT

If PICCU have an audio issue then check the audio volume in settings at PICCU, for settings password is “1234 Setting has an option of volume. Select volume it has an option of SET volume by virtual jog dial if volume comes then you should check connection of coach speaker. If issues are not resolved then contact service engineer

14 LHB POWER If LHB is not powered up then you should check voltage . Voltage should be at power connector 110V. If issues are not resolved then contact service engineer

15 LHB COMMUNICATION

If LHB is not showing the status online at the PICCU screen then check the communication connection at PICCU. It should be Issue of loose cable. If issues are not resolved then contact service engineer

16 ETU POWER IF LHB is not powered up then you should check voltage . Voltage should be at power connector 24 V. If issues are not resolved then contact service engineer

17 ETU COMMUNICATION

If ETU is not showing the status online at the PICCU screen then check the communication connection at PICCU. It should be Issue of loose cable. If issues are not resolved then contact service engineer



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18 WATER LEVEL Check water level RS-485 cable at PICCU. It should be Issue of loose cable. If issues are not resolved then contact service engineer.

8.9. Automatic Hinged Door (BONY/IMI) S.No Error/Fault Action Required

1 HMI not able to Start

Check the power supply is available.

Check the wiring connection.

Check for any physical damage sign of HMI. If so HMI may require replacement or manufacture repair service. Contact to original manufacture.

HMI touch screen not working, in this case clean the surface with agent cleaner smoothly.

Check the Communication connection with HMI.

Check the electrical wire and communication cable for any damage.

2 Push Buttons Not

working:

Connect the millimetre’s wire to port of push button and check for the connectivity after pressing and depressing of push button.

If Button is not changing their polarity from NO to NC or vice versa after pressing push button, it means push Button requires replacement.

Check the wiring connection if get loosen, tighten them.

3

Main Actuator Failure with symptoms as

below:

Continuous leakage of air

Jerky door operation

Unable to do the door operation

If actuator is having air leakage, noise, jerky operation. Remove the Main Actuator, unscrew all fittings. Add Teflon tap and Loctite at all threads and tighten them. If still problem is not resolved replacement of actuator will require. Steps to be followed

First remove the local door protection cover.

Remove the pneumatic connection from actuator.

Unscrew the bolts which mount the actuator on Shell plate Asm.

Check for the problem, Air leakage, physical damage and others.

Take corrective actions.

4

Control Block Failure with symptoms as

below:

Door operation failure

Air Leakage

Jerky and Fast door operation

Check the solenoid, if failed replaces the same.

Check the wiring connection, if loosen repair them.

Check the valve spool is shifting when supply is on.

If all above not solving the problem replace the control block

5 Emergency Reset/

Mechanical Locking valve Failure with symptoms

Check the solenoid, if failed replaces the same.

Check the wiring connection, if loosen repair them.

Check the valve spool is shifting when supply is on.



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as below:

Mechanical Locking System failure

Air Leakage

If all above not solving the problem replace the valve

6

Mechanical Locking Arm Failure with symptoms

as below:

Problem in door locking and unlocking

Problem in door unlocking when emergency button pressed.

If system is unable to perform, replace the system.

7

Power supply Connection Failure with

symptoms as below:

SMPS not able to give 24vdc output

Wire broken/damaged

If power supply failed to perform, replace with new one

8.10. Infotainment System (FUNTORO) S.No Error/Fault Action Required

System

1 System power not

turning on. Check fuse on power panel

Monitor

2

Monitor no power (6 monitors or 3

monitors no power in same HUB)

Check HUB power cable & HUB fuse

3 Monitor no power

(1 monitor no power)

Replace this monitor to Other seat & check power on or not.

Change monitor.

Check mega cable or HUB mega port.

If required change mega cable.

If required change HUB

System Network

4

System Network Error Ethernet from server is

not working

Check SERVER giga out signal light green always light and orange flashing.

If not change server

5 Check HUB giga in & out whether direction is incorrect

If required modify all HUB giga port direction

6 Check HUB giga in & out cable connector is good or

not.

If required change damaged giga cable

7 Check HUB giga in & out signal light green not light and

orange not flashing



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Change the HUB

8 If still can’t find problem

Pull out all giga connection & keep one giga connection from SERVER to 1st HUB in & check monitor loading

(If Monitor loading good) Addition 2nd HUB connect from 1st HUB out & check monitor loading

(If Monitor loading good) Addition 3rd HUB connect from 2nd HUB out & check monitor loading

(If Monitor loading good) Addition to final HUB connect from previous HUB out & check monitor loading

SSD

9 SERVER Can’t read SSD content or all monitor can’t show main menu

Check SSD disk format for which system (MOD or SuperHD)

Copy all content & profile again

10 Can not copy all content

& profile Change SSD

11 Cant read content &

profile Change SERVER SATA interface board.

(I still cannot read) Change SERVER

8.11. Water Level Indicator ( Amit Engineering) S.No Error/Fault Cause Action Required

1

Loose wiring connections

1. Wiring connections without lugs and undersized lugs.

2. Wiring connections tightness not checked properly after installations.

1. Use proper sized wire lugs and ensure to use wire lugs for all wiring connections.

2. Check properly the tightness of the wiring connections after installations the equipment.

2

Display indicators not display any signal

1. Loose wiring connections.

2. Wrong wiring connections

3. Faulty display.

1. Tight the connections properly and use wire lugs.

2. Check wiring connections properly and rectify if any misconnections.

3. Replace the display unit with new one.

3

Floats rises or falls with the liquid level- Switch de-activated

1. Miswiring. 2. Cables broken. 3. Float travel stop is in

improper position. 4. Reed switch is in

improper position. 5. Reed switch is

damaged. 6. Liquid immerse in

sensor.

1. Wire correctly. 2. Replace cables. 3. Adjust position of float travel stop. 4. Adjust position of reed switch or

float. 5. Replace reed switch. 6. Replace sensor.

4

Floats doesn't rises or falls with the liquid level.

1. Build-up on float or stem

2. Specific gravity of liquid too light.

3. Float is filled with

1. Clean float and stem. 2. Change the proper float. 3. Replace float. 4. Use spacer. 5. Replace float.



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water. 4. Float is in contact with

stilling tube. 5. Float damaged by over-

pressure. 6. Float is swelled or

corroded.

6. Replace compatible float.

5

Switch chattered

1. Loose cables 2. Waves or disturbances

in tank. 3. Install in wrong

location.

1. Tighten connections. 2. Use stilling tube. 3. Install in good location.

8.12. SEAT -180 DEGREE ROTATABLE (VISTADOME) S.No Error/Fault Cause Action Required

1 Seat flops back not in use

Loose tension spring and broken mechanism

Replace and install mechanism.

2 Seat jerks forward while seated

Commonly a worn away the pivot pin metal mechanism

Replace mechanism

3 Nothing happens while activating lever

In proper usage of lever Replace of lever and its continuity parts

8.13. ELECTRICALLY CONTROLLED OPALESCENCE – ROOFTOP (PrivaLite) S.No Error/Fault Action Required

1 A Component (cable,

connector, control unit) are broken or damaged.

To follow maintenance procedure and solve properly.

Check wiring and sensor circuit

2 Nothing appears in the

display screen when control unit is turned on

Charge the control unit battery .if problem check the wiring circuit

3 Broken glass Check roof top glass around sealant area.

LHB_Tech_Development_Volum... - RDSO - Indian Railway

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